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When a machine shop is known for its precision parts, it can be risky to step into the world of high-speed CNC machining. Speed certainly adds efficiency, but it doesn’t have to jeopardize quality when you are working with quality equipment, well-trained staff, and you employ control monitoring with credible CNC software suppliers. Rapid Tool has enjoyed a long-term relationship with Mastercam which allows working CNC machines at high speeds with confidence.
Design Translation
Utilizing software to accurately apply G codes to a three-dimensional design is the first key to high-speed machining. There is software available for anything from the home hobbyist to high precision software and you get what you pay for. When you can utilize a 3D model you can see the toolpath onscreen. This presents the best scenario for work holding and identifies any errors in the tooling approach before the project begins. Good programs will cover design and simulation with cost estimation and data management support.
Tool Challenges
Tool breakage and wear is a high cost in CNC machining. Tools can cost from thousands to tens of thousands of dollars. Some production runs may require a special tool purchase to be used only one time. This results in breakage becoming a very costly process. The idea of running high speeds can make a machinist wary due to heat and wear caused by friction, or toolpath errors where damage can occur.
Utilizing software that programs the tool to rarely lift away from the part seems, at first, like the wrong approach. Intelligence software actually increases tool life. In 5-axis CNC machining, for example, the tool and spindle can be so close to the part that shorter tools can be employed. Shorter tools are less susceptible to breakage. But what about those high speeds?
Mastercam Dynamic Motion Technology answers those concerns. The toolpath is continuously monitored with immediate feedback to the software driving the machine. This allows the tool to stay in constant contact with the part as it changes in shape and size throughout the machining process. Tool wear is reduced with less vibration and breakage is rare, if at all, with such accurate tool paths and sensors.
Precision and Speed
The exacting movement of the cutting tool monitored through the Dynamic software can reduce processing time from 25% to 75%. There are no air cuts, nor is it necessary to continually reset the toolpath to centre. The tool simply moves through G code sequences relative to the shape of the part.
Shorter tools mean faster and more accurate cuts. Increased contact with the machined part also results in reduced machining time. Speed is always a factor in efficiency, but with software monitoring and feedback there is no loss of quality. Corners and finishes are clean and efficiencies are also realized through less machine downtime.
Learning Curve
The philosophy of machining changes when moving from manual to CNC machining. It takes time and training to adjust to the capabilities of a machine with tool changers and pallet changers where the job of the machinist becomes supervisory. This same philosophy applies to embracing software like Mastercam Dynamic Motion Technology. Running high speeds with the tool in almost constant contact with the part leaves machinists and operators with trepidation of tool breakage and machine damage.
The best approach to working CNC machines at high speeds with confidence is to ease into the process as machinists and operators become more trained with the software capabilities. Always start with direct training from the software provider, and continue a good relationship for troubleshooting and service. Soon you will realize the reduced change for human error and the accuracy and efficiency are the way forward for your machine shop.