EdgeCAM Waveform Data - Manufacturing Technologies Group

Report
:Waveform Event
Vero Software Limited
Hadley House, Bayshill Road, Cheltenham, Gloucestershire, GL50 3AW, UK
Page 1
Waveform Agenda
•
•
•
•
Introduce Edgecam Waveform Technology
Edgecam Waveform Testing
Where to find Edgecam Waveform data
Q&A
Page 2
Unlocking Your Machines Potential
Page 3
Unlocking Your Machines Potential
Higher
Feedrates!
At deeper
Depths!
Page 4
Maximum
RPM!
Think About Every Part You’ve Cut
How deep
can I cut?
How fast
can I cut?
How much
stepover can
I take?
Page 5
Deeper…
After all, if you cut in a straight
line, you can machine …
At higher RPM…
WHY?
With a larger stepover…
And FASTER!!!
Page 6
(video)
Traditional Toolpath Review
Page 7
Straight line vs. corners
•The challenge with traditional toolpath / shape offset machining
Material Engagement
50% of Cutter
100% of Cutter
10mm End Mill at 50%=5mm
Page 8
10mm End Mill at 100%=10mm
180 Degree Engagement
Feedrate Override!!
Page 9
Traditional vs Waveform
Page 10
Edgecampedia
Waveform
This new roughing strategy is
a high speed machining
technique that maintains a
constant tool cutting load by
ensuring the tool engagement
into the material is consistent.
The tool path moves in a
smooth path to avoid sharp
changes in direction which
maintains the machine tool’s
velocity.
change in velocity
acceleration =
time
Page 11
Edgecampedia
Waveform Pattern
• Helical plunges into pocket
• Imitates straight line cutting
• Maintains constant chip load
• Reduces intermittent cuts
• Tool is engaged with material
longer without lifting
• Reduces Cycle Times
• Smooth tangent toolpath
•Reduces wear and tear on
tools, holders, and machine
•Works with 2D or 3D Roughing
Page 12
Edgecampedia
Waveform Properties
• Deeper Depth of Cut (DoC)
• Use full Flute Length
20% WoC
• Manages Width of Cut (WoC)
• Controls Chip Thickness
• Generating Faster Feedrates
•Constant Feedrate
DOC = 2.5 x Tool Diameter
• Superior Speeds
•Consistent Tool Load
Page 13
Edgecampedia
Automatically Adjusts
• Maintains consistent material
removal by adjusting width of cut
• Maintains chip thickness and chip
load
• Concave areas
• Width of cut decreased
• Convex area
• Width of cut is increased
Page 14
Edgecampedia
Waveform Links
• Links are aware of rapid and High
Feedrates
• Waveform uses fastest method
• Localized areas stay at depth
• Long Links retract and rapid
Page 15
New in 2012 R2
Waveform Enhancements
• Tapered Helical Plunge
•3 Degree Taper
• Percent Speed adjustment for
Helical Plunge
• Optimized Mill Type
•Alternates Climb/Conventional
• Improvements to Arc Tangency
Page 16
Edgecampedia
Waveform Ease of Use
• Uses standard Roughing Cycle
• Simple Interface
• 3 Modifiers To Adjust
• Minimum Radius can also be
used
Page 17
The Hard Part
Getting Started
“Not on my machine you don’t!!”
•Finding machine time
•Test straight line test cutting
•Run until tool breaks and back off
20%
•Add Test Data in Waveform Cycle
•DO NOT Adjust Feedrate Override
during cycle
•Slowing down will burn up cutter
“Wow, I didn’t know my machine
could do that!!”
Page 18
Waveform Test
Traditional Toolpath
Tool Size
RPM
Feed
DOC
%Step
Cycle
Time
16mm
2600
1000mm/Min
5mm
30%
63 min
Waveform Toolpath
Tool Size
RPM
Feed
DOC
%Step
Cycle
Time
16mm
5000
3000mm/Min
20mm
18.5%
18 min
Machine: Mazak Vertical Centre Smart 430 A
Material: P20
Tooling Provided Courtesy of Sandvik
Cycle Time Reduce By:
45 min = 71%
Page 19
Waveform Test
Traditional Toolpath
Tool Size
RPM
Feed
DOC
%Stepover
Cycle
Time
.500 4FL .06R
1500
16 ipm
.125
30%
42:32
Waveform Toolpath
Tool Size
RPM
Feed
DOC
%Stepover
Cycle
Time
.500 4FL .06R
10,000
196 ipm
1.00
18%
4:15
Machine: Mori Seiki MV-653
Material: 4140 Rc: 28-36
Cycle Time Reduce By:
Tooling Provided Courtesy of Sandvik
38 min = 90%
Page 20
Waveform Live
Page 21
Waveform Data
Page 22
Waveform Data Sheets
Page 23
Questions
Page 24
Questions
I ran Waveform at the same feeds and speeds
with my usual settings and it wasn’t any faster.
Why?
Waveform was designed to cut significantly faster and deeper than
traditional toolpaths. If you run at the same parameters (Spindle
Speed, Feedrate, Axial Depth of cut, Radial Depth of Cut) as with
traditional toolpaths, you are driving a Ferrari at Yugo speeds. Run
Waveform toolpaths to their capability and it will be unbelievably
faster.
Page 25
Questions
Does Waveform require specialized tooling?
Reviewing your entire process, such as tooling, work holding, and
coolant will bring further cycle time benefits. When using your existing
tooling, Waveform users will see improvements in cycle time, tool life,
and machine maintenance cycles.
Page 26
Questions
Does Waveform require higher-end/highspeed machines with expensive options?
No, some of the largest performance increases to date have been
realized on older basic machines. Waveform toolpaths can be run
much faster and deeper than any traditional toolpaths due to
constant tool load.
Page 27
Questions
I’m a job shop and I don’t run production.
Most parts are one off’s. How will I benefit
from Waveform?
Waveform users can quote lower machine rates compared to non
users or charge the same rates and run more hourly jobs per
week/month/year. Not to mention extended tool life from constant
tool load and reduced machine maintenance cycles.
Page 28
Questions
Will I only see cycle time improvements in
Aluminum parts?
Actually, Waveform is even more impressive in hard materials.
Overloading the tool is much more severe in harder materials than in
softer materials. Since Waveform never overloads the cutting tool,
hard materials can be cut at very aggressive material-removal rates.
Page 29
Questions
Why doesn’t Waveform adjust feedrates?
Other CAM systems that provide toolpath similar to Waveform, do no
adjust engagement in convex and concave corners. This giving
Waveform an upper hand. Since constant chip thinkness is calculated
through corners, no feedrate adjustment is required. Waveform
either reduces it’s % stepover or increases depending on the cut.
Page 30
: Thank you
Questions?
Page 31

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