PowerMILL processes medium application in high speed milling

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The development of CNC Machining equipment and high-powered cutting tool makes high speed processing technique mature with each passing day, raised a mould to machine speed greatly. Regard a mould as the important step of treatment, high speed milling is become in recent years a arisen kind of advanced processing technique. High speed treatment is used high rotate speed, fast feed, small cut be apart from greatly with half step improve treatment efficiency, jumping-off place is the cutting below condition of high speed small negative charge. High speed basically is main shaft high speed, feed high speed and idle stroke high speed. Small negative charge is meant can reduce cutting force, the vibration in reducing cutting process thereby and be out of shape. Use appropriate cutting tool, fall in high speed condition but the material of cutting tall horniness. Major heat in metal cutting is taken away through cutting bits, the heat that decreased to avoid a spare parts even thereby is out of shape. Because cutting of this high speed has cutting power process of small, treatment good, efficiency mixes quality of smooth, treatment high can realize pair of hard data (＜ 60HRC) and spare parts are delicate a lot of advantage such as structural treatment. Logarithm of high speed cutting accused software of automatic process designing to raise taller requirement: The campaign that 1) holds a machine tool is successive, flowing the stability that assures cutting tool bear thereby, avoid cutting tool overload; The cutting tool way that 2) makes is successive, reduce knife of advance and retreat as far as possible, inverting uses the means that circular arc transfers as far as possible, those who assure contrail of cutting tool motion is smooth, avoid the abrupt change of knife direction and acceleration, the feed that keeps stable moves; 3) whole journey has been prevented automatically cut processing capability and examination of collision of automatic knife handle; 4) can offer the abundance that accords with high speed to machine a requirement to machine strategy. PowerMILL is compositive be based on a variety of knowledge, particular treatment means that are based on craft feature and whole journey to had been prevented cut, apply to the function such as high speed treatment, can offer a good solution to the whole production process of the mould, it is the software of CAM of high speed treatment that an intelligence converts. The following union machines example, the course of treatment process designing that introduces PowerMILL and mould high speed machine strategy and method. One, PowerMILL machines process designing measure 1.

Be record in a model to PowerMILL can use PowerSHAPE direct model or read in files of a variety of CAD of commonly used mainstream through PS-Exchange module, make full use of the advantage of all sorts of software, improve the efficiency of process designing and quality greatly thereby. 2.

Parameter set (the set that 1) coordinate fastens builds treatment coordinate is common ground the following principle: Take working coordinate department to be fastened to machine coordinate commonly; Coordinate origin should be in surely be helpful for measure and fast and accurate the position to the knife; The position that goes up in the machine tool according to department of machine tool coordinate and spare parts machines the direction of reference axis certainly. To accord with treatment habit, use place implement fasten center of the surface on the spare parts origin to put work as coordinate, z direction also can be in the top part of workpiece or lowermost place according to circumstance setting. (The set of size of 2) semifinished product is in PowerMILL, semifinished product is patulous the set of the value is very important. If should be worth the computational amount that sets so that cross a general to increase an order, increased the time of process designing, if set too small, the program will have consideration for the limit with the size of semifinished product, interference appears when treatment of so probable some face does not reach the designated position or beginning to be machined actually, the set with so patulous semifinished product is general the radius that is more than treatment cutting tool a bit according to set of size of real semifinished product, consider its surplus even at the same time. (The set that feed of set of 3) treatment parameter leads, set of feed height, set that begins dot and end drop, cut the basis such as the set that cuts the set with join means and cutting tool particular treatment working procedure and treatment are politic and calm. Name and connection of cutting tool dimension had better provide the knife to rise when set cutting tool among them, if the name calls the knife of D6R2 to be 6mm on behalf of cutting tool diameter, round horn radius is the round horn knife of 2mm. Such naming when be helpful for process designing, be opposite of cutting tool choose and check. 3.

Craft analysis and work out decide what feature can be installed in finish in clip, arrange treatment order and use cutting tool, use certainly finally why to plant treatment means will finish. After the choice machines means, need defines size range of pipe bent and treatment parameter. After defining parameter, finish the computation of contrail of cutting tool motion by software, can undertake machining emulation. If cutting tool contrail is not ideal, can revise parameter and make calculate or have an edition to cutting tool contrail directly afresh. 4.

Emulate after reaching postposition processing to generate contrail of all cutting tool, can transfer into machine tool file undertakes emulation, handle a program to be its changeover treatment G code through special postposition. 2, PowerMILL high speed machines politic PowerMILL to be able to achieve all sorts of pair of CNC Machining orbit generate, editor and postposition processing, still can be opposite at the same time generated treatment contrail undertakes emulation with desired result, do not have with making sure generated CNC Machining program is precise by accident. In mould treatment, from regular form semifinished product the spare parts to the front of finishing is handled is machined, treatment craft can divide milling to machine 4 working procedure for rough machining, semifinishing machining, finish machining and clear part commonly. 1.

The main goal of rough machining of rough machining strategy seeks the material purify rate inside unit time, make follow-up semifinishing machining or finish machining surplus even, what assure rough machining cutter track is smooth, efficient. Because cleared milling means has outline area to surround efficiently,cutting walks along knife and feed setting, have at the same time knife function fills between the layer, because this is the most commonly used rough machining means. Its fall cut or the part transfers to should use the knife below the knife below inclined or circular arc between travel, take the treatment kind of suitable mill as far as possible, the light that the pointed part part of cutting tool method wants to use round part arranges processing to be stabilized in order to assure cutting tool bear, reduce the abrupt change of cutting force. If pitch on limits option of cutting tool overload, surplus identifying function can be in the intelligence of software to be versed in the area such as quantity, complete Dao Kuan, corner decides automatically substantially use cycloidal treatment, namely cutting tool moves along the curve that has certain radius, with material of purify of successive of way of circular arc movement, have high speed to spare parts surface small cut deep treatment, the kind that can prevent cutting tool effectively to cut work with complete Dao Kuan makes cutting tool way, make the machine tool carries successive feed rate in whole treatment process, accord with high speed to machine a requirement thereby, prolong cutting tool life. Strategy of the following treatment uses as far as possible in rough machining namely: Use what begin outward treatment from the center of workpiece to slant as far as possible buy treatment is politic, in order to reduce complete knife wide cutting; In cutting tool the area of easy occurrence overload uses cycloidal treatment, if the graph is shown 1 times, can improve treatment efficiency, prolong cutting tool life, lessen the impact to the machine tool. For the biggest the pointed horn corner in changing the ground to eliminate cutting tool method, use cycle racing line to machine (the patent high speed of Delcam machines means) , if the graph is shown 2 times, in order to carry constant cutting tool bear and platoon bits rate, make cutting tool bear more stable, improvement machines quality. 2.

The target of semifinishing machining of semifinishing machining strategy is to make level off of workpiece outline appearance, exterior mental allowance is even, the high speed milling that is finish machining prepares. Regard the treatment that is based on knowledge as software, powerMILL can identify the rudimental area of on one working procedure and corner area automatically, automatic differentiate undertakes cutting between the step that on one working procedure remains, system but intelligence changes the ground to optimize cutting tool method, make surplus keeps even as far as possible, avoid to appear a large number of empty knives, make the cutting load of cutting tool smoother, cutting tool contrail is fluenter. 3.

The target of finish machining of finish machining strategy is the optimal surface quality that the design that machines a contented spare parts asks and outline precision. PowerMILL offerred a variety of finish machining strategy to back different finish machining kind, be like three-dimensional slant buy finish machining, etc expensive precision work, optimal wait for expensive precision work and parallel finish machining. Choose treatment strategy to have the following principle commonly: Optimize parallel treatment, the light that uses round part in the pointed part part of cutting tool method arranges processing, can improve treatment efficiency significantly, prolong the life of cutting tool, lessen the impact to the machine tool; Helix 3D slants buy treatment, avoided parallel treatment strategy and slant the abrupt change of the frequent direction that buy appears in treatment strategy, raise treatment rate thereby, reduce cutting tool to wear away; Optimal wait for tall treatment, powerMILL system can use area automatically to analyse algorithm to be handled respectively to area of abrupt peace calm, computation suits to wait to be reached high suit to use similar 3D to slant the area of buy, and can use helix means at the same time, carrying rarely optimized cutting tool way is made below the circumstance of the knife, acquire better exterior quality. Nextpage4.

The treatment of horn of local Qing Dynasty after clear part machines finish machining to finish is quite serious also. PowerMILL has a variety of clear part kind, often use part of automatic Qing Dynasty (Corner Automatic Finishing) machines means, the system can use area beyond to lead analytic algorithm, undertake automatically handling respectively to abrupt or even area, and the basis machines craft, use in abrupt turning point wait for high fashion to make cutting tool way, in even area along cutting tool method and edge root direction is full automatic the ground is machined from the move back and forth inside extroversion, in order to ensure surplus is even, make sure cutting tool method is flowing, cutting load is even. 3, the target that the optimizes high speed treatment cutting tool method of method taking a knife optimizes is experience of contented have nothing to do with, mix glossily without collision, contrail cutting load is smooth, should make sure the treatment precision of the spare parts and exterior surface roughness ask at the same time. The cutting tool method of PowerMILL is optimized main from means of knife of advance and retreat, move knife means and corner walk along a few respects such as the knife to undertake. 4, the punch that if the graph is shown 3 times,uses treatment actually, the over all dimension of semifinished product is 240mm of × of 400mm × 250mm, according to the structural characteristic of the mould, working procedure cent machines 4 working procedure for rough machining, semifinishing machining, finish machining and clear part. Graph 3 punch rough machining keeps clear of with outline area treatment means, cutting tool uses D30R5 of round nose knife, helix leaves a sword, gou Xuangao fast treatment options, avoid to machine directional mutation to cause the sharp change of cutting tool load. Cutting parameter: Feed speed is 6000mm/min, cutting deepness is 2mm, main shaft rotate speed is 4000r/min, mental allowance is 0.

8mm. Step face exists on the workpiece after rough machining, semifinishing machining is used wait for means of expensive precision work, if the graph is shown 4 times, use cutting tool D20R0.

4 round nose knives, tick off circle of take as an elective course and helix, decrease carry the knife makes cutter track suitable slippery. Cutting parameter: Feed speed is 4800mm/min, cutting deepness is 0.

3mm, main shaft rotate speed is 12000r/min, mental allowance is 0.

3mm. Graph finish machining of method of cutting tool of 4 semifinishing machining has side of curved surface peace considering spare parts surface, undertake machining apart so. Among them, if pursue 5, the straight grain side that the graph shows 6 times uses SWARF precision work. Use diameter is 12mm, the round horn knife that radius of point of a knife is 1mm (D12R1) , choose a plan the curved surface that 5 shadows part has SWARF is machined. Method of cutting tool of 6 SWARF of figure of face of treatment of graph 5 SWARF sets cutter shaft for automatic. Of Z height pass by a distance distance 5mm is cut below 20mm, cut cut a setting to be horizontal circular arc (angle 90 ° , radius 6mm) , short / long / safe join is set to flit, drive curve chooses the side outside curved surface, direction arranges mill, do not leave surplus. Duplicate and primitive sheet the method of cutting tool of SWARF finish machining of method, use D10 carries milling cutter and handle the cutting tool way that bottom produces anew to caving on its and sidewall, if pursue 7 with the graph 8 are shown. Nextpage graph 7 SWARF machines method of cutting tool of district plan 8 SWARF to use D16R0 next.

4 balls knife with optimal wait for expensive precision work to machine others, control next cutting with rudimental height step pitch, short join setting is on curved surface, carry in order to decrease knife. Cutting parameter is: Feed speed is 2000mm/min, rudimental height is 0.

1mm, main shaft rotate speed is 10000r/min, mental allowance is 0.

5mm. After finish machining, be in bottom and round part part to be able to leftover material was not machined, because this needs clear part process. The measurement that uses PowerMILL the part of the smallest R that the function measures a workpiece is 11mm, choose milling cutter of D10 ball head accordingly, by many clear part treatment means undertakes clear part is machined, if pursue,9 are shown. Graph method of cutting tool of many 9 clear part is when process designing, undertake through software cutting tool clip supports collision inspection, lest add man-hour happening accident. Go to to load of generated method of all cutting tool same a NC program is medium, pass emulation imitate finally, on the computer simulation cutting tool moves, with preventing a knife the mistake is mixed unreasonable take a knife, if pursue 10 with the graph 11 are shown. Graph 10 emulation results pursue the 11 NC programs that one air produces first when calling file of the double machine tool that place a head to emulate postposition to handle, the NC program that adds way of generated 6 cutting tool strong generation " 1 " in, if pursue,12 are shown. In NC program " 1 " in right attack click " setting " , if the graph shows a dialog box 13 times,appear, file of selection process name, output and file of machine tool option (namely aftertreatment file) , be in next NC program " 1 " right attack click " write " , the output that can install in place produces a machine tool to process requires G code below file directory. Graph method of cutting tool of 12 to load comes NC program 5, the main factor that the cutting tool way that place of process designing of NC of treatment of last word high speed makes is quality of influence mould treatment, accordingly, the specific need that should machine according to high speed, actor choosing machines method and cutting tool to take knife kind, can make the treatment of mould product achieves the goal of life of high quality, efficient, longevity, small time limit for a project and low cost. CNC Milling