Using advanced CAM-systems for optimized HSC-machining of complex free form surfaces

Abstract

High speed cutting (HSC) offers the opportunity to significantly reduce machining times as well as to minimize manual rework for complex free form surfaces in the die and mould making industry. To achieve the best results it is also necessary to apply HSC-suitable machining strategies to perform optimal high speed milling operations. This paper presents a method to use free form features to improve the automatic generation of high speed machining information for specific geometric areas to create HSC free form manufacturing features. By examining the geometrical and topological information of the work piece’s virtual model, the feature elements can be extracted and joined with the required information. This covers several important high speed cutting aspects in the CAM system, like optimal technology and strategy suggestion, machining safety requirements and process stability of different strategies. Using this approach the programming time to produce HSC appropriate tool paths is reduced significantly, while it is quality is secured

Advanced Machining Technologies for Parts with Complex Walls

“…It may be noticed that the link between the vibration amplitude and the surface roughness is too complex to give predictive values. High speed cutting aspects in the CAM system, leaded to a significantly reduced programming time to produce high speed cutting appropriate tool paths [6]. These high speed cutting aspects may be: optimal technology and strategy suggestion, machining safety requirements and process stability for different strategies.…”

Experimental investigation of effect of tool path strategies and cutting parameters using acoustic signal in complex surface machining

“…Schützer et al developed an approach to use complex features to enhance the automatic creation of milling data. Their approach reduces the programming time significantly to produce HSC appropriate tool paths for same quality [13]. The objective of the observation of cutting processes are related to the productivity of the milling center, cutter life, surface tolerances/texture properties, cutter flexibility/deflection, and other parameters of the part as well as the chip geometry, generation and classification.…”

Comparison of Milling Strategies when Machining Freeform Surfaces

“…Programming time within HSC technology can be 2-3 times longer than time of machining. In conventional metal cutting, machining time represents longest time period of production chain [12]. Longer programming time is not caused only by reducing of machining time, but mainly by extending the time required to create NC program.…”