New Delcam video shows Vortex high-efficiency roughing strategy

DELCAM’s new video showing an Iscar Finishred 12mm cutter on a Mazak Variaxis 750 programmed with the PowerMILL CAM system used in machining a 4340 alloy steel presents the Vortex high-efficiency roughing strategy in area clearance. It underscores that the Vortex strategy yields the fastest safe metal removal from solid carbide tooling and provides designs that give deeper cuts by using the full flute length as the cutting surface.

The roughing strategy can be used for two- and three-axis roughing, three-plus-two-axis area clearance, and rest machining. It is also suitable for machining all types of materials, including titanium, tool steel, and alloys such as Inconel.

By producing toolpaths with a controlled engagement angle, the Vortex keeps optimum cutting conditions for the toolpath, usually possible only for straight-line moves. With the resulting higher feed rates, cutting is done at a more consistent volume-removal rate and constant federate. The cutting time is reduced and the machine is protected. 

The Vortex’s constant feedrate differentiates it from other high-speed roughing techniques, as shown in Delcam trials. The approach is also more reliable because it is not easy to predict the reaction of machine tools to changing feedrates.

The minimum radius parameter used in the Vortex is calculated to make sure that the machine tool can maintain the cutting feedrate in corners and for any nonstraight part of the toolpath.  This ensures the machine runs at the programmed feedrate throughout and not slow down on other kinds of area-clearance toolpath, thereby also ensuring predictability.

With the Vortex strategy, the control of the engagement angle ensures predictability in the performance of the tool, which operates closer to the optimum cutting conditions associated with a straight-line cut.  This facilitates an easy adjustment of the feeds and speeds used to machine a particular part so the tool can be relied on to cut multiple components before changing becomes necessary.  The program can accommodate a tool change for a safe and consistent lights-out machining on a long series of parts.