Delcam's 5-axis machining and high-speed machining system PowerMILL 20 14 was officially released. The most dazzling new function is Delcam's patented vortex high-speed area cleaning strategy for cyclone milling.
Cyclone milling eddy current is a patented machining strategy developed by Delcam for cemented carbide tools. By adopting this strategy, the surface of the part can be cut by using the full cutter groove, thus significantly improving the machining efficiency of rough machining of cemented carbide tools and maximizing the potential of cemented carbide tools. This strategy can be used for 2-axis and 3-axis rough machining, 3+2-axis area cleaning machining and residual machining based on residual blank or reference tool path.
Like other Delcam rough machining strategies, cyclone milling strategy always follows the outline of parts, thus minimizing the idling of tools and obtaining more efficient tool paths. This is especially important for the remaining processing.
In its own workshop, Delcam uses different machine tools and tools to actually process and inspect different types of parts. The experimental results show that the cyclone milling strategy can greatly improve the rough machining efficiency and shorten the machining time. The improvement of machining efficiency is related to the shape of the machined parts and the machine tools and tools used. This strategy can easily shorten the processing time by at least 40% regardless of the machine tool or part type. The cutting results of SGS Z-Carb MD tool on a Huron machine tool show that the machining time can be shortened from the original 12 1 minute to only 34 minutes by adopting the vortex strategy of cyclone milling, saving 7 1%.
One of the basic problems of the traditional region cleaning strategy is that the cutting conditions can only be optimized on the straight path, and the contact angle of the tool needs to be significantly increased when machining any corner position in the model. In order to protect the cutter, it is usually necessary to reduce the feed speed at the corner. For this reason, users either choose to use this low feed speed all the time in the whole tool path to maintain a constant feed speed, which will inevitably extend the processing time; Or we have to choose to use variable feed speed and rotational speed in model processing, which will increase tool wear.
Ordinary high-speed rough machining technology always wants to keep a constant theoretical metal cutting speed, but cyclone milling strategy is different from them. It controls the contact angle of the tool in the whole machining process, so that the contact angle is always kept in an optimized state, thus maintaining the optimized cutting conditions that can only be achieved through linear motion throughout the tool path, thus shortening the machining time, obtaining more stable volume cutting speed and feed speed, and protecting the machine tool and the tool.
Because the contact angle is controlled by the trajectory of the cyclone milling cutter, there will be no tool overload, which will make the tool life longest. At the same time, the vibration load of the tool caused by the change of contact angle will be eliminated, and the appearance of slot pin will be prevented. In addition, the stable cutting conditions also make the cutting edge of the tool have a stable temperature, which can prolong the life of the tool coating and eliminate the thermal damage on the surface of the part. Finally, the use of undercut steps 2-3 times larger than the diameter of the tool can make the tool wear evenly distributed on the cutting surface of the whole tool and further prolong the tool life.
"Anyone who has used the vortex cyclone milling strategy can immediately hear the difference in sound processing between this strategy and other processing strategies. Mr. Mark Forth, product manager of Delcam Advanced Processing Solutions, said. The traditional rough machining produces different tones, which indicates that the tool has overload and vibration, while the rough machining of eddy current and cyclone milling produces the same tone, which indicates that the tool runs under stable cutting conditions. Users can also see that the size and thickness of the cutter pin produced by vortex cyclone milling strategy are very uniform, which is difficult to achieve by conventional rough machining strategy. "
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