SURFWARE NEXT Courtesy of SURFWARE, Inc. SURFWARE 30% - 70% reduced cycle times 2x to 4x increase in cutter life Higher quality parts.

SURFWARE

NEXT

Courtesy of SURFWARE, Inc. www.surfware.com

SURFWARE

• 30% - 70% reduced cycle times

• 2x to 4x increase in cutter life

• Higher quality parts

Welcome to TrueMill®

This presentation will show you how TrueMill can increase your Return On Investment, by:

SURFWARE

NEXT


Do you realize that your existing CNC equipment’s performance is being

restricted?

SURFWARE

NEXT


To find out your equipment’s true machining potential, cut in a straight line at the edge of a block as fast and as deep as the cutter and machine will safely allow.

Do you agree that if you always cut in a straight line at the edge of a block, you could use dramatically more aggressive parameters than if you cut a real part?

Why can’t you use these aggressive parameters for any part?

SURFWARE

NEXT


Tool Engagement Angle (TEA) is the angle about the periphery of the cutter which is in contact with

the material while milling.

Stepover is a constant value (often defined as a percentage of the cutter diameter). Traditional

CAM toolpaths are created by offsetting the part geometry by the stepover value in the radial direction of the material to be

removed.

TEA

Stepover

SURFWARE

NEXT


In this slide, we are machining in a straight line to show a 50% stepover which, in this condition, equates to 90-degrees of TEA.While we machine along, let’s observe the effect on spindle load as well.

SURFWARE

NEXT


Notice the spindle load went up a bit. Because now we’re taking a 75% stepover, which on a straight line equals 120-degrees of TEA.

SURFWARE

NEXT


What happens on inside arcs and corners?

Hey! The spindle load just jumped over 100%. What happened? We are still cutting with the same 75% stepover. Ahh, we machined into an arc or corner. As you can see, the TEA jumped to 165 degrees.

SURFWARE

NEXT


Tool Engagement Angle directly correlates with Tool Load.

SURFWARE

NEXT


What happens on inside arcs and corners?

A 180-degrees of TEA indicates full burial. As inside arcs and corners get smaller, with respect to a given stepover, full burial conditions are common.

SURFWARE

NEXT


Traditional constant stepover toolpath

Most CAM software produces tool paths that inherently overload cutters on inside corners and arcs. This is commonplace. So what can we do? Typically, we are forced to machine at very conservative depths and speeds to compensate for these critical areas.

NEXT


SURFWARE

NEXT


toolpath engine

The patent-pending TrueMill tool path engine is the first since the inception of CNC milling that controls constant TEA. TrueMill eliminates the critical machining areas. It machines any part at depths and speeds similar to cutting at a straight line along the edge of a block with constant cutting speed, feedrate and depth of cut. This ensures that the width and the length of the chip remain constant and that the material removal rate is high and constant.

Courtesy of SURFWARE, Inc. www.surfware.com NEXT

SURFWARE

NEXT


toolpath engine

The TrueMill process also eliminates most of the chatter and buildup of high temperatures of the cutting tool, the two primary killers of carbide endmills. All of these benefits enable your milling machine to perform at its true potential.

Courtesy of SURFWARE, Inc. www.surfware.com NEXT

SURFWARE

NEXT


Compare TrueMill versus Traditional

• Let us do a side-by-side comparison of what happens to TEA on a part.

• We will compare TrueMill at 120-degrees of TEA (which equates to 75% stepover in a straight line cut) to Traditional tool path at a lighter stepover of 50% (which equates to a desired 90-degrees of TEA in a straight line cut).

SURFWARE

NEXT


Traditional

120° Tool Engagement Angle

50% Stepover


Here’s the fundamental difference between the two strategies. Traditional CAM’s focus is on maintianing constant stepover…

NEXT


SURFWARE

NEXT


Traditional

120° Tool Engagement Angle

50% Stepover


… while the revolutionary TrueMill engine’s primary focus is on managing the tool’s constant engagement angle.

SURFWARE

NEXT


Chart the Tool Engagement Angle

Traditional

0

20

40

60

80

100

120

140

160

180

Traditional Toolpath Desired TEA

0

20

40

60

80100

120

140

160

180

Toolpath Desired TEA

Early on, we can see how the Traditional has already fully buried the cutter at least twice.

The TrueMill TEA and cutter load stays at or below the pre-defined threshold.

NEXT


SURFWARE

NEXT


Chart the Tool Engagement Angle

Traditional

0

20

40

60

80

100

120

140

160

180


0

20

40

60

80100

120

140

160

180


NEXT


SURFWARE

NEXT


Traditional

0

20

40

60

80

100

120

140

160

180


0

20

40

60

80100

120

140

160

180


These are typical graphs of every part that is machined with TrueMill and Traditional CAM software tool paths.Traditional CAM tool paths not only exhibit fluctuations of TEA and tool load, they frequently overload the cutter. This induces high temperatures and vibration in the tool, both causing shorter tool life. Therefore, you are forced to machine slower and at shallower depths of cut in order to compensate for these critical overload areas and the erratic tool loads.TrueMill safely stays below the desired TEA! Thereby, you can safely increase feed rates by a factor of 4x to12x, increase spindle speeds by 2x to 4x and safely increase the depth of cut by a factor of 2x to 4x, achieving overall increase machining output of 30% to 70%!!!

NEXT


SURFWARE

NEXT


Bryan Romero

Quality Machining & Design

Titanium Computer Cartridge

.1875 Endmill

“The return on investment withcan be realized almost immediately!”

w/o TrueMill Results

Depth of Cut .100 .335 (full depth) 235%

Spindle Speed 3056 6000 98%

Feedrate 12 52 333%

Cycle time/part 1 hour 34 min. 43%

Cost to run job $20,000 $11,333 $8,667

Cutting tool life 35 parts 200 parts 470%

TITANIUM

SURFWARE

NEXT


Jorge Sousa,Owner, J&E Precision

Aerospace Job Shop

w/o TrueMill Results

Cycle time/part 37 mins 22 mins 40% faster

Flatness/part .035 in .015 in 57% Flatter

Creates higher quality parts

SURFWARE

NEXT


SURFWARE

The entire cutting environment becomes constant:

: Performance Summary

• Constant force on the tool • Constant chip thickness • Constant feedrate • Constant tool deflection • Constant tool temperature • Constant Material Removal Rate

SURFWARE

NEXT


SURFWARE

• Can be used with any existing CAM software

• Can increase return on investment

• 30% - 70% reduced cycle times

• 2 to 4 times longer cutter life

• Higher quality parts

THANK YOU

Courtesy of SURFWARE, Inc. www.surfware.com END

SURFWARE NEXT Courtesy of SURFWARE, Inc. SURFWARE 30% - 70% reduced cycle times 2x to 4x increase in cutter life Higher quality parts.

Documents