True Mill Training Manual

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rueMillTraining Manual

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TrueMillTraining Manual

Table of Contents

INTRODUCTION .................................................................................................................... 1OPEN SOLIDWORKS FILE IN SURFCAM ............................................................................. 2

MACHINING OFTHE PART .................................................................................................... 4

TRUEMILL

FOR POCKET FEATURE ................................................................................. 5TRUEMILL

FOR STEP FEATURE .................................................................................... 14

TOOLPATH VERIFICATION.................................................................................................. 17

DETERMINING MACHINING PARAMETERS FOR TRUEMILL

................................................ 19TRUEMILL

SAMPLE TESTING RESULTS ............................................................................. 20

TrueMill

is a registered trademark of Surfware, Inc.

Copyright 2007 by Surfware, Inc.

This manual is protected by U.S. copyright, international treaties, and other applicable copyright laws and may not bereproduced, distributed or sold without the express permission of Surfware, Inc., which reserves all rights. Reuse of any ofSurfware content and graphics for any purpose without Surfwares permission is strictly prohibited.

While every precaution has been taken in the preparation of this manual, Surfware assumes no responsibility for errors oromissions, or for damages resulting from the use of the information contained herein

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Introduction

TrueMillis the best roughing software for most applications and materials. TrueMill is proven to

increase profits by dramatically reducing machine cycle times. Longer cutting tool life and higherquality parts are also a benefit of TrueMill.

Traditional high-speed machining uses smaller depths of cut and stepovers than regular toolpaths. In dramatic contrast, TrueMill enables even greater depths of cut and stepovers at higherfeeds and spindle speeds.

TrueMill maximizes the capabilities of your existing CNC equipment as follows:

TrueMill dynamically controls the tools engagement with the material to create fluid toolpaths and eliminate spikes or sudden changes in tool load.

This steady tool engagement enables much more aggressive spindle speeds, feedrates,depth of cut, and stepover. Use speeds, depths, and stepovers that would damage thepart or break the tool if used with traditional tool paths.

These aggressive parameters greatly reduce cycle times.

This steady engagement dramatically reduces tool wear and the smooth efficient mannerin which material is removed is also easier on the machine which lowers machinemaintenance costs.

Higher quality parts are also inherent with TrueMill. More heat is transferred to the chip,away from the part, resulting in much less part deformation.

Included with this manual is the example file used in the manual. Please create a folder namedTraining Manualin the \SURFCAM\Samples\folder as shown below. Then uncompress/unzipthe provided files in this folder.

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Open SolidWorks file in SURFCAM

The part that is used in this section was created in SolidWorks. The file was saved in theSolidWorks native format, with the SLDPRT extension.

To open the SolidWorks file in SURFCAM click on File, Openand browse to the\SURFCAM\Samples\Training Manualfolder.

Set the Files of Typeto SolidWorks Files (*prt,*sldprt)and select TrueMill.sldprt

The native SolidWorks file gets loaded in SURFCAM. Click on the Shaded with Wireframe

button. Then switch to Isometric view by holding Ctrl + 7.

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If you check the Layers dialog box, you can see that SURFCAM automatically placed the surfaceand the wireframe elements on two separate layers:

To change the options that apply to SolidWorks files, click Tools, Options and then selectFiles,Read, SolidWorks/Parasolid

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Machining of the Part

This part has a Pocketand a Stepfeature that will be machined by using the TrueMill

technology.

TrueMill is Surfwares high-speed machining solution for any machine tool. TrueMillenables the

tool to maintain higher speeds because all abrupt direction changes are replaced with smooth,tangent tool motion. Smooth high-speed repositioning moves also replace the rapid moves,allowing the machine to stay in the high-speed mode continuously during the entire cycle.Because of these enhancements, toolpath feed rates can be increased and cycle times reduced.

The tool engagement angle (TEA) is a key setting in TrueMill. SURFCAM creates the toolpath sothat the actual engagement angle of the tool never exceeds the value you specify.

Tool Engagement Angle = 90

You create a TrueMill operation the same way you create the conventional Pocket and Contouroperations. However, the TrueMill pocketing option creates a superior tool path.

In the sections below we discuss the machining of each of the parts features.

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TrueMillfor Pocket Feature

Click on NC, 2 Axis , TrueMill

Make sure that the selection mode isset to Chain

Select the pocket boundaries by clicking twice on 1. The selected chain changes its color. Thenselect Done

The TrueMill dialog gets displayed. Click on the Select Toolbutton and select 0.5 dia - 2 flute Endmill

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Click on the Select Materialbutton, select 6061-T6 Aluminumand click OKon the SelectMaterial dialog.

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Click on the Common to >tab and set the parameters as shown. Since we selected Aluminum,we will use machining settings that are suitable for this material. Remember, TrueMill enablesyou to use more aggressive spindle speeds, feedrates, depth of cut, and stepover.

In this section we focus on the settings that are critical to create an optimum TrueMill toolpath:

Geometry is the:select the top radio button

Choose the option that matches the profile you select to create theoperation.

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Set Depthto0.5This setting specifies the total depth of the cutting operation.

You can also use thePick Z Depthbutton to specifythe depth of a pocket

When you click this button , the dialog box is removed temporarily and the SelectPoint menu is displayed. The Elementscommand is displayed and highlighted.

If you select the vertical line, thedifference between the values of theZ coordinates of its end pointsbecomes the Depth.

Minimum RadiusUse a minimum radius to avoid excessive small movements, especially in sharp corners.This reduces inefficient motion during a radial cut, thus saving machine time andreducing tool wear.

Example:Minimum Radius = 0 Minimum Radius = 0.25might produce excessive small radial cuts reduces unnecessary radial cuts

Plunge Type:click ontheHelix buttonYou can set the Helix Radius and the Ramp

Angle of the helical plunge move.

Accept the default values.

Set High Feed Rateto 800 IPMThe High Feed Rate is to the maximum linear (not rapid) feed rate value of your CNCmachine. Every positioning move (between engagements) is done at this high feed rateas opposed to a rapid move.

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The TrueMill toolpath contains both rough and finish cuts. As shown below, you can set differentfeed rates and spindle speedsforRoughingand Finishing.

Set Feed Rate(rough) to 650 IPMSet Feed Rate(finish) to 400 IPM

Set Spindle Speed(rough) to 12,000 RPMSet Spindle Speed(finish) to 10,000 RPM

Click on the Rough/FinishtabYou can notice three groups of settings that apply to the different cuts: Rough, Finish FloorandFinish Walls.

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This is the side view. The arrows indicate the Helix Clearance.

Tip:If you want an arc instead of a helical move, set the HelixClearance to 0.

Set Engagement Clearance to0.01 inThis is the linear distance from the material to the tool where the feed rate changesbetween the High Feed Rate and the Feed Rate.

This feed rate change may take place part way through a helical Lead In/Out move.

The High Feed Rate moves in the lower left corner areshown in bold line type. The arrows indicate theEngagement Clearance.

2. Finish Floor settingsClear the Finish Floorsetting. In this example we do not finish the floors.

Note:Typically you increase the finish Tool Engagement Angle to finish the floor. If you dontneed to manage the Tool Engagement Angle on the floor, you can create a subsequenttraditional pocket operation.

3. Finish Wallssettings

Select the Finish Walls check boxThis option creates a finish cut on the walls.

Select the Make One Cut at Netcheck boxCheck this box to make one finish pass that leaves no stock on the walls.

Select the Make 1Spring Cutcheck boxCheck this box to create 1 or more additional cutting passes at net (no stock).

Clear the Cutter Compensationcheck box

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Check this box to create cutter compensation moves before the lead-in and after thelead-out moves for Finish Walls. In the illustration below, the Cutter Compensationmoves are shown in bold line type. The arrows indicate the Cutter CompensationDistance.

OFF ON

The Cutter Compensation Movecan be perpendicular or tangent.

Set Final Finish Cut Overlapto 0.05 inUse this setting to prevent a mark left by lead-in and lead-out moves at the samelocation. The final finish pass continues past the start location by the value you enter, andthen the lead-out move takes place.

Set Lead In/Out Radiusto 0.05 inThis is the radius of the finish walls cutting moves into and out of the material.

Set Helix Clearance to 0.005 inThis works the same as Helix Clearance under the Rough headings, but applies only tothe lead-in and lead-out moves for the Finish Walls cutting passes.

Click OK

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SURFCAM creates the TrueMill toolpath to machine the pocket feature:

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The TrueMill dialog appears:

SURFCAM should default to the same tool and the same machining parameters that were usedfor the previous TrueMill operation. If necessary, set the parameters as shown in the previous

section.

Click OKon this dialog box.

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SURFCAM creates the TrueMill toolpath to machine the step:

Important Tip: For clarity, the pocket and the step feature were programmed with separateoperations. TrueMill was designed to program multiple features in one step. Try for yourself byprogramming both features with a single operation.

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Toolpath Verification

The SURFCAM verification lets you simulate the cutting operations. To verify the operations youfirst need to define the material stock and then run the verification

Follow these steps to specify the material stock:

Open the Operations Manager.

Right click the mouse on Setup Oneand selectEdit Setup Information

The NC Section Informationdialog appears.

Select the Stocktab:

Click the GeometryBounding Boxbuttonto automaticallycalculate thecoordinates of theopposite corners of the

material box.

ClickAdd

Now select OK

Note: the material stock gets saved with the SURFCAM file

Now you are ready to run the verification of the cutting operations.

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Open the Operations Manager dialog

Make sure that Setup Oneis highlightedand click on the Run SURFCAM Verifybutton

From the verification toolbar select the Playbutton

The verified part is shown below

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Determining machining parameters for TrueMill

TrueMill was designed to cut faster and deeper than traditional toolpaths. So how do you set thespindle speed, feed rate, tool engagement and the rest of the machining parameters for yourapplication? Here is a simple technique to get started.

1. Make straight line test cuts along the outside edge of the material. Start with your usualcutting parameters except double the tooling manufacturers recommended chip load.

2. Monitor the spindle load meter. If load is less than the desired amount, incrementallyincrease the Spindle Speedwhile maintaining the increased chip load from step 1. Thefeedrate will therefore increase.

3. Test combinations of increased Spindle Speed, deeper Depth of Cutand/or larger ToolEngagementAngle until desired spindle load is achieved. Typically with TrueMill, 100%spindle load can be safely utilized.

4. Use these final parameters in the TrueMill operation page every time you use that specificcombination of machine, cutter, and material regardless of the shape of the part.

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TrueMillsample testing results

As a reference, below is data compiled from test parts:

Material

Machine

RatedHP

Tool Type / Make

ToolDiameter

No.ofFlutes

SpindleSpeed

Programmed

Feedrate

AxialDOC(Ae)

TEA(degrees)

Chiron FZ15W Fanuc 18Mi 29 Iscar Carbide Endmill .500 in 3 12000 855 IPM .500 in 120

DMG DMU 50 HeidenhainTNC530

17 Iscar Carbide Endmill 12 mm 3 10000* 15000mm/min

9 mm 122

Fadal Cat 40 (year 1983) 20 Kennametal carbideUncoated, 37 Helix

.500 in 3 10000* 400 IPM* .500 in 101

Fadal Cat 40 (year 1993) 20 Kennametal carbideUncoated, 37 Helix

.500 in 3 10000* 525 IPM* .500 in 100

Haas VF2 SS 29 OSG BlizzardPart #204149

.500 in 3 12000* 756 IPM .500 in 120

Haas VF2 SS 29 Iscar Carbide Endmill .500 in 3 12000* 840 IPM .500 in 120

Haas VF3 SS 29 OSG BlizzardPart #204149

.500 in 3 12000* 630 IPM .500 in 120


Haas VF4 (year 1997) 20 OSG Blizzard

Part #204149

.500 in 3 10000* 300 IPM* .500 in 120

Haas VF5 30 Kennametal carbide

Uncoated, 37 Helix

.500 in 3 7500* 400 .500 in 100

Haas VM2 20 OSG Blizzard

Part #204149

.500 in 3 12000* .500 IPM*

run 200%ovrd.

.500 in 120

Haas VM3 20 Iscar Finishred 12 mm 4 12000* 500 IPM*run 200%

ovrd.

.500 in 120

Hurco VMX 42 24 DataFlute

Carbide Endmill

.500 in 3 10000* .500 IPM* .500 in 95

Mazak NEXUS VCM 510C 20 OSG BlizzardPart #204149

.500 in 3 12000* 420 IPM* .500 in 120

Mazak 510C Mazatrol 240 30 DataFlute

ALDH 30500 C5

.500 in 3 14000 600 IPM .500 in 140

Mori-Seiki NV4000 DCG(VMC)

25 Generic bargainendmill

.500 in 3 12000* 630 IPM .500 in 120

Alum

inum6

061T6

Mori-Seiki NV4000 DCG

(HMC)

25 Generic bargain

endmill

.500 in 3 14000* 784 IPM .500 in 120

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Material

Machine

RatedHP

Tool Type / Make

ToolDiameter

No.ofFlutes

SpindleSpeed

Programmed

Feedrate

AxialDOC(Ae)

TEA(degrees)

Cincinati FTV 640 20 DataFluteSSST 40250 C1

.250 in 4 7154 65 IPM .350 in 100

Cincinati FTV 640 20 DataFlute

SSST 40375 C1

.375 in 4 5100 55 IPM .400 in 100

Cincinati FTV 640 20 Helical 14317 .500 in 4 4200 55 IPM .400 in 100

SteelA2

27-30Rc

Makino S56 40 ISCAR

ECI-E5L-625-1.56C62CF IC900

0.625 9000 404 IPM 1.5 56

SteelP

20

28-32Rc

Kia VX500 20 DataFlute

Carbide Endmill

.500 in 4 3100 50 IPM .700 in 120

Mazak 510C Mazatrol 240 30 DataFluteSSI 40500 C11

.500 in 4 5600 80 IPM .500 in 140


SSI 40500 C11

.500 in 4 7200 120 IPM .500 in 140Steel1018

Haas VM3 20 Iscar Finishred 12 mm 4 12000 500 IPM .500 in 64

Haas VF2 15 Iscar Carbide Endmill .500 in 4 7500 500 IPM* .500 in 36

Steel1020


Steel1040

Haas VM3 20 Iscar Finishred 12 mm 4 9700 500 IPM .500 in 64

Steel4140

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Material

Machine

RatedHP

Tool Type / Make

ToolDiameter

No.ofFlutes

SpindleSpeed

Programmed

Feedrate

AxialDOC(Ae)

TEA(degrees)

Steel4142 Haas VF3 20 Iscar ECPI Chip

Splitter

E3L 500 -

1.0/1.5C500IC900

12 mm 3 5500 396 .375 in 45


SSDH 40500 C11

.500 in 4 6500 100 IPM .500 in 80

Makino S56 15 OSG EXOCARB 0.75 4 6500 125 IPM .700 in 54

StainlessSteel420

28-30Rc

*Indicates a maximum value for this specific machine. SURFCAM Velocity is the first CAM software that willrequire machinists to consider their machines maximum values.

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