Maximising machine efficiencies

Since the dawn of machining, the manufacturing industry has looked for ways to squeeze greater efficiencies out of existing equipment, materials and labour. Computer-aided manufacturing (CAM) and computer numerical controlled (CNC) machining were huge steps in the right direction several decades ago. But in recent years, we have seen only small, incremental improvements in machining productivity.

This is because research focused primarily on computerisation to streamline toolpath generation, and on expensive toolpath “optimiser” software, slowing feedrates at corners to reduce stress on tools. Nearly all innovations assumed a parallel-offset toolpath used for roughing out parts – not realising that this was the real bottleneck.

A breakthrough technology changes all this. Ultra-high performance toolpath (UHPT) software improves the way that tools cut their way through material, using high-speed continuous tangent motion rather than sharp, interrupted movements. Field applications prove that UHPT technology can safely double machine output, extend tool life, and create a much more productive competitive manufacturing enterprise in the global marketplace.

Avoiding the corners and stop signs
Imagine driving through a neighbourhood without arterial streets. At each corner, you must slow down or stop at a stop sign, make a turn, and proceed for another block, always encountering changing traffic conditions. Or think of a rural road that skirts the perimeters of various farmers’ fields, filled with tractors and trucks. Slow down, pass stop, turn, go, sharp turn, go. Slow down. It’s maddeningly inefficient.

That’s how basic toolpaths drive today’s CNC machines. Modelled on manual methodology, existing toolpaths are derived from the geometry being machined. They start with the material boundary and keep stepping in, following the shape of the material, regardless of efficiencies, until the path collapses on itself. In other words, the tools follow a path regardless of the amount of material they encounter. They slow down, sometimes stop, change direction, and cut again, sometimes encountering excessive material, other times little material. This is very hard on both machines and tools. Now return to the neighbourhood, and imagine it redesigned on a circuitous route, with carefully banked roundabouts and smooth curves instead of corners and stop signs. The amount of traffic is steady; it almost never slows down and never comes to a halt. You drive at a high average speed until you reach your destination. Yes, you might travel a bit further in distance. But the time you save, the fuel efficiency, and the reduced wear and tear on your car make the circuitous design well worthwhile. This is the underlying concept behind UHPT technology.

How it works
UHPT technology works on any shape, open or closed, with any number of features, and integrates with any CAM system. It plans the toolpath based on abilities designed into the machine and cutting tools. By taking advantage of the capabilities of modern machining hardware and avoiding sharp directional changes, it generates toolpaths that assure the machines and cutting tools are used at peak efficiency given existing conditions. Currently a 2.5-axis product, UHPT software is ideal for prismatic parts. It easily cuts pockets, steps, slots, channels and other shapes, and can handle an unlimited number of material and part boundaries and islands. It can be used with any cutting style and material, including the hardest metals. Traditional toolpath technology forces machinists to accommodate worst case machining conditions to prevent damaging the spindle and wearing out the cutting tool. Abrupt changes in the amount of material being encountered put excessive force on the part and machine. So programmMujer