Production Milling

Benefits

 

Intelligent Roughing Cycle

Edgecam’s advanced roughing cycle for the machining of both 2D and 3D component parts can be applied to the complete model, providing consistent performance on all types of model. Laced, concentric and spiral machining strategies can be implemented as well as “bottom to top” intermediate slicing between Z-levels. This intelligent cycle automatically applies the most efficient approach move for each region of the model and creates trochoidal moves to avoid full width cuts. The ability to define 3D stock reduces machining time by eliminating air cutting.

Edgecam’s roughing cycle also incorporates rest roughing, where stock is automatically defined by the preceding roughing cycle, so the smaller tool only creates a toolpath in the areas that the larger tool could not access.

Within the inclusion of “Prismatic” and “High Speed cornering” controls, Edgecam offers the user total control over their NC output allowing consistent and accurate programming.

Profiling Cycle

Edgecam’s profiling cycle allows you to generate toolpaths on 2D geometry, 3D sculptured shapes and solid models in one easy to use cycle. The main advantage to the user is a consistent interface and support for advanced features and functionalities in both 2D and 3D environments. This intelligent cycle offers cusp height and cut increment control, thus producing excellent surface finishes for both steep and shallow regions. Using integrated cutter radius compensation, the cutting side is determined and compensation calls generated automatically between multiple profiles and levels.

Highly effective controls can be used to determine the start and end positions for the profiling cycle. A full set of corner rounding strategies allows you to choose the most appropriate method for machining corners.

The cycle offers full Helical machining support which includes Cutter Radius Compensation support. When working in the 3D environment, the cycle allows “Undercut Machining” in conjunction with “Lollipop” and “ Tee-Slot” cutters.

Prismatic Machining

Facemill Cycle

This cycle optimizes the use of facemill tooling and can be utilized on parts with planar features such as walls, bosses and other flat areas. The cycle allows you to define the area to be machined by selecting a boundary. Nested boundaries are supported, and resulting toolpaths are associative to their respective feature boundaries.

Multiple machining strategies are offered as well as a comprehensive array of Lead and Link control parameters.

Thread Milling

Internal, external, single and multi-start threads are programmed to provide canned cycle support.

Hole Cycles

Drilling, reaming, boring and tapping cycles are all supported. Edgecam’s ‘hole optimization' calculates the shortest path for machining a set of holes plus, offers the user several methods of pre-determining the hole start position. Moreover, the cycle offers “lace band width” for more complex hole patterns thus reducing cycle times and excessive machine tool travel.

Maximum productivity is achieved through solid model associativity. Feature Level, Depth and Tooling specifications  are driven from the solid model, thus offering seamless manufacturing process and secure toolpath technology.

3D Machining

Parallel Lace

One of the most popular strategies,  Parallel Lace offers machining flexibility as it is able to produce solutions for both Roughing  and Finishing techniques. This is achieved by simultaneously controlling Stepover, cusp height and cut increment This intelligent cycle takes parallel cuts along the part, and allows for three different machining strategies.

Combinations of “Boundary control” are offered as well as regional machining options. The cycle incorporates cross-cutting methodology by offering Contact Angle and Perpendicular Lacing controls.

Used in combination with profiling, a consistent surface finish can be maintained by defining the cut angle. This angle specifies where the strategies meet on sloping shapes.

Constant Cusp Finishing

This cycle generates a toolpath by continually calculating an accurate 3D Cusp value thus allowing EdgeCAM to maintain a constant surface stepover from one pass to the next. It produces a toolpath that can be defined from a drive curve and produces a superior surface finish as well as allowing the user to control the “Grain” of the toolpath.

Projection Finishing

Projection machining is a method of finish machining a part according to its design. It applies the required surface finish and cut pattern quickly and easily over the whole model or discreet features.
Edgecam’s Projection Finishing strategies allow

  • A 2D toolpath to be projected onto a 3D surface
  • A circular pattern where, radial, concentric or spiral strategies are projected onto boss or pockets features thus producing a unique surface texture.
  • A pair of flow curves to drive a lace toolpath along or across a surface

Pencil Milling

The Pencil Milling cycle is used to clean up left-over material from a previous finishing cycle. Pencil Milling can either execute a single pass along internal edges and intersections or, multiple passes where the toolpath is controlled by Stepover

Rest Finishing

Similar to Rest Roughing, the Finishing cycle is used to clean up material remaining from a previous. One can choose either Bullnose or Ballnose cutters when working with the cycle.

Machining can be optimised by allowing the Rest Finishing Cycle to take a “Pencil Cut” around the part.

Similar to all edgecam cycles, the command offer extensible boundary, Lead and Link controls.

Plunge Roughing

Capturing the latest in cutting technology, EdgeCAMs Plunge Roughing cycle exploits one of the most extensively used, rapid materiel removal methods, known through the metal cutting industry.

Plunge Roughing is primarily used for machining pockets and external stock - in deep mould and dies for example. Long tools gain stability from a cutting force directed up the tool axis rather than as a side force.
Material is removed as a series of concentric passes. The tool works around the part using 'Recommended Stepover(%)' and 'Maximum Forward Step' parameters.

Flat Land Finishing

This cycle automatically detects the flat areas on the model and applies a lacing or concentric clearance pattern on these areas. The cycle is ideal for parts possessing multiple Z-levels, such as Microwave and Satellite systems components.

Common to most edgecam Operations and Cycles, the command offesr extensible boundary, Lead and Link controls as well as Rest Finishing capability

Combined with the Parallel Lace cycle for the machining of steep areas, it provides the most efficient strategy for the machining of free-form components, by ensuring that the most appropriate tooling is used for the machining of different areas of the model.

Multi-Axis and Multi-Plane Machining

When machining multi-faced parts, or multiple parts mounted on a tombstone fixture, Edgecam can easily position to any face to allow full use of both prismatic and 3D machining cycles. Machining sequences and toolpaths can be merged into a single sequence and rationalised by tool, index position or datum to produce an optimal program. Edgecam Simulator displays all the multi-axis and rotational multi-plane moves for realistic process simulation and collision checking.

Production Turning

Grooving Cycles

External, internal and face grooving are all simple tasks with Edgecam. Side grooving cycles enable the programmer to produce sophisticated machining strategies that take advantage of advanced tooling design.
Where Swarf congestion is produced or when “ribbons” of material can potentially foul the machine, EdgeCAMs Rough Grooving cycle offer “Peck Increment” control.

Thread Turning

Taper, single and multi-start threads are easily programmed to provide canned cycle or longhand support.

4-Axis Turning

Using Edgecam, machines with twin turrets are easily programmed and synchronised for maximum efficiency. Balanced and mirror cutting cycles exploit the metal removal capabilities of multi-turret machines. Individual turret control and turret synchronisation ensure maximum efficiency. Separate instruction lists for each turret allow easy editing of synchronisation points and machining instructions.

The Balanced Turn Cycle maintains chip flow by offering the user a “Lead” parameter within the command.

Edgecam Simulator provides full 4-axis representation of the upper and lower turret, providing sequence verification before the machining process commences.

Sub-Spindle Turning

Edgecam includes an easy-to-use multi-axis turning module for programming sub-spindle lathes. As with multi-turret machine configurations, cycle time and the ability to turn a part completely in one operation are of paramount importance when working with sub-spindle lathes.

Integrated commands to control activities associated with sub-spindle lathes make programming easier. Main features include:

  • Integrated lathe setup command guides you through machine and job setup.
  • Spindle selection is made easy with a single mouse click and the instruction browser indicates clearly which spindle each instruction is for.
  • For twin turret lathes the side-by-side view of the instruction browser offers an ideal programming environment. The turret synchronisations are lined up and, to inhibit conflicting spindle codes being programmed, turret priority is clearly indicated.
  • Synchronisation positions can be moved around to reduce machine idle time and a time line view of the instructions across spindles and turrets is useful for program verification.
  • Sub-spindle pick off is simple to program using a combination of Spindle Docking, Part Off and Move Sub-spindle commands and is very flexible.
  • simulated simultaneously. Batch simulation of the machining job includes animation of the sub-spindle pick off and bar feed for full program verification.

B-Axis Machining

Single set-up machining is the key to boosting metal cutting productivity when milling and turning are done on the same machine tool. Edgecam provides full support for B-axis machining on a mill/turn machine tool, allowing Edgecam users to benefit from the wide range of milling and drilling cycles by applying them to the B-axis of multi-configuration machine tools.

B & C-axis orientation commands make rotary positioning easy. Having indexed to a face the full power of Edgecam machining cycles are now available to you. The Maintain Index function on the toolchange command reduces command input when multiple machining operations are carried out at the same index position. Realistic simulation of the B-axis in Edgecam Simulator offers full program verification.

C- and Y-Axis Mill/Turn Machines

The complete range of Edgecam’s milling and hole machining cycles can be implemented on mill/turn machines. Edgecam allows driven tooling to be programmed for machining on the face or the diameter of a component. Switching between Y- and C-axis modes is a single click process.

As with other cycles, Edgecam Simulator provides realistic graphical verification, ensuring that programs are correct before being executed. Both milling and turning activities can be verified, showing rotary movement of the stock and chuck during C-axis milling.

For the more complex of Mill/Turn machine tools, one an exploit EdgeCAMs 4/5 Axis Simultaneous machining capability.

Features

Production Milling

 

Edgecam provides the production machine shop with a wide range of flexible milling Operations and Cycles. Milling Operations allow the user to quickly produce a basic toolpath via a simple text and picture driven dialog box. An intuitive interface guides the user through a series of machining decisions. Ideal for irregular or novice programmers.

Underpinning Edgecam's Operations is a full and comprehensive suite of Milling Cycles. Each cycle offers the very best that technology can offer thus allowing the modern day machinist to achieve total toolpath control.

Machining efficiency is maximized on simple and complex prismatic parts as well as those incorporating sculptured surface geometry. With Edgecam you get prismatic machining combined with powerful 3D solid and surface machining strategies, all in one complete solution.

Prismatic Machining

Edgecam's prismatic machining functionality offers a comprehensive range of combined 2D & 3D machining cycles, helping you to maximize your productivity.

Surface Machining

Recent trends in component design have resulted in an increased need to incorporate complex shaped geometry in production machining. Previously, such requirements were limited to short run, or one-off machining environments such as the mold, die and prototyping industries.

Edgecam offers a full range of 3D machining functionality that can be used by the production machinist equally effectively to machine large quantity batches. Free form Surface shapes and Solid models are machined using innovative, reliable and gouge free cycles. Intelligent approach strategies provide improved surface finish while optimizing machining times and maximizing tool life. Adaptive leads and links ensure collision free entry and exit on and off the job.

Multi-Axis and Multi-Plane Machining

Edgecam supports the machining of holes, pockets, bosses and 3D complex shapes on multiple faces of the component part, reducing total setup time and taking advantage of multi-axis machine capabilities. Edgecam offers full support for multi-axis milling, including 2½D and 3D machining, 4-axis rotary machining, 3+2-axis positional indexing and 5-axis simultaneous machining for trimming, and de-flashing of single surfaces.

Production Turning

Edgecam Turning provides functionality for a wide range of machine tools, including 2-axis lathes, multi-turret configurations, sub-spindle turning centers and mill/turn machines. On a mill/turn machine, C-, Y- and B-axis machining take place within the same turning environment thus providing a fully integrated and associative programming solution. Ease of use and an understanding that cycle times are critical, especially on multi-configuration mill/turn machines, underpin the development of Edgecam's turning functionality.

Edgecam produces advanced rough and finish turning cycles, together with support for facing, boring and drilling in either canned cycle or longhand format. Toolpath calculation takes into consideration the complete tooling insert and previously machined material to avoid gouging and eliminate air cutting.

Edgecam offers support for Sandvik Coromant Wiper inserts for turning tools, allowing these productivity enhancing inserts to be used reliably in all aspects of production machining.

 

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About ATS

ATS is the leading manufacturing CAD/CAM/CAE and Shop Floor Monitoring solutions provider for manufacturing companies in the Midwest and Southeast United States. We provide consulting services, software, and support to automate mechanical industrial manufacturing companies.

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