extending nx cam with cnc feedrate optimization · extending nx cam with cnc feedrate optimization...
TRANSCRIPT
Extending NX CAM with CNC Feedrate Optimization
Lee Fowkes
CGTech UK
PLM Europe - Siemens PLM Connection 2018Berlin, October 2018
Last Revised LF 23-Oct-2018
Subjects for today
• Why is VERICUT the most popular Independent G-Code Verification product for NX users?– VERICUT plug-in for NX CAM– NX ConnectTM bi-directional interface– Teamcenter MRL Tool Library Interface– Teamcenter PLM Interface*
• Feedrate Optimization of NX Toolpaths• Verification of Additive Manufacturing
FOR PUBLIC USE
NX Connect
• Logger lists issues
• Highlights Operation to revise
• NC Programs - Right First Time!
10/23/2018 FOR PUBLIC USE
New Teamcenter MRL Interface
FOR PUBLIC USE10/23/2018
• VERICUT 8.2 reads tools directly from Teamcenter MRL
• Tooling stays stored in Teamcenter
• No duplication on local drivesTeamcenter MRL Tool Assy
Teamcenter MRL Workflow
10/23/2018 FOR PUBLIC USE
Siemens NX Mfg Project
Teamcenter DB
MRL
Teamcenter
Interface
VERICUT Tool Manager
Teamcenter
Connection
Siemens NX Tool Creation
Searching
FOR PUBLIC USE10/23/2018
• Search NX Tool assys
• Select to Import
Searching
FOR PUBLIC USE10/23/2018
• Search for NX Projects
– Manufacturing only
• Finds all NX Tool Assysin the NX project
• Select All or individual to use in VERICUT
10/23/2018 FOR PUBLIC USE
Teamcenter Revision Checking
10/23/2018 FOR PUBLIC USE
• Reopening a VERICUT session using tools from Teamcenter checks revisions of cutting tools
• Any ‘out of date’tool are flagged
• Tooling data always up to date
• Reduce machining time
• Faster time to market
• Avoid out-sourcing
• Improve part quality
• More consistent results
• Less time deburring
• Longer tool life
• Avoid tool breakage
• Stay competitive
Reasons to optimize
New Machine Tools
New CAM System or path strategy
New Cutting Tool Technology
Many strategy choices
Many strategy choices
• Will a cutter chip, or break?
• How long will your cutters last?
• Will excessive cutting forces damage, or move the part?
• Will a cutter load up with material, or stall the spindle?
Confidence in NC Program Feedrates
• Any existing, or future NC program, G-Code or CLSF, 2-5 axes
• Created by any CAM system or other source
• Run on any CNC machine tool• Cut by any brand cutting tools
Can be made to run faster and better!
Focus on NC optimization
Manufacturing Workflow
VERICUT Usage Flow
AUTO-DIFFAdditive Mfg.
OptiPath/Force
Grinder-Dressing
Optimization
Data
Optimized
Toolpath
CAD/CAM
Interfaces
CA
D/C
AM
Syste
m(s
)
Tooling
Interfaces
& Import
Tool M
gm
tS
yste
m(s
)
3D Models
Fixtures
Design
Machin
e S
hop
Control
Machine
Kinematics
Cutting
Tools
Toolpath
Reports
Screen Display
Stock
• Variables, Subprograms,
Macros
• Subroutines, Looping
and branching log
• Multiple synchronized
CNC controls
• Look-ahead or 3D cutter
compensation
• Tool tip programming &
tool length compensation
• Gage length reference
point programming
• Canned cycles and
fixture offsets
• Rotary axis pivot points
• Auxiliary mechanisms
• Force material
characterizations
• Known good cutting
conditions
• Data gathered from
learn mode
• Log file
• X-caliper results
• AUTO-DIFF report
• Tooling report
• Optimization results
• Inspection sequence
• Setup plan
• Reviewer (PC or iPad)
• Transfer from CAM
• Transfer from Tool
Management interface
• Download from “Cloud”
• Request from tool manuf.
• Model in CAD
• Model in VERICUT
• Obtain from MTB
• Obtain from CGTech
• Model from 2D drawings
• Measure machine
• Custom configuration made by CGTech
• Template VMC provided as-is
• Library VMC included with VERICUT
VERICUT Machine
Configuration (VMC)
Force
Calibration
OptiPath/Force
Optimization
Data
Optimized
ToolpathForce
Calibration
Methods of Optimization
Air Cuts Only – Increase feedrates when the tool is not in contact with material (cutting in air)
– No risk of changing cuts or machined finishes on part
OptiPath– Optimization based on Chip Load and Volume Removal, or both
– Relies on User knowledge of Material type and Cutting capabilities
– Easily manipulated with settings and limits
Force– Optimization based on optimal Chip Load, and considering Force or Power limits
– Relies on cutter-to-material “characterization” data obtained via dyno-testing
– Physics-based force calculations, also takes into account cutter rake and helix angles
Air Cuts Only Optimization
• Increases feedrates for off-part motions in air
• Reduces time of proven NC programs, without changing cuts or surface finishes
• Outputs new “optimized” NC program
• Available to ALL VERICUT users
Time savings can be substantial!
Air Cuts Only Optimization
How it Works
3 EASY steps:
1. Turn on "Air Cuts Only"
3 EASY steps:
1. Turn on "Air Cuts Only"
2. Simulate
How it Works
3 EASY steps:
1. Turn on "Air Cuts Only"
2. Simulate
3. View your savings!
How it Works
Optimized Results• “Compare Files” original v optimized NC program• Highlights changes
Red= original codes
that were modified in
the optimized file
Blue= modified codes
in the optimized file
Methods of Optimization
Air Cuts Only – Increase feedrates when the tool is not in contact with material (cutting in air)
– No risk of changing cuts or machined finishes on part
OptiPath– Optimization based on Chip Load and Volume Removal, or both
– Relies on User knowledge of Material type and Cutting capabilities
– Easily manipulated with settings and limits
Force– Optimization based on optimal Chip Load, and considering Force or Power limits
– Relies on cutter-to-material “characterization” data obtained via dyno-testing
– Physics-based force calculations, also takes into account cutter rake and helix angles
OptiPath Optimization
• Variety of strategies available• Control over chip loads, material removal rates,
adjustments available for “special” cutting conditions• Calculates optimized feedrates based on cutting
conditions encountered• Optimized programs are safer, faster, more efficient• “Learn Mode” availableMore (usually MUCH more) savings than Air Cuts alone
OptiPath Optimization
How OptiPath Works
• Each Tool is assigned an OptiPath record• OptiPath records describe how to optimize
feeds and speeds for various conditions• OptiPath micro-analyzes each cut, and
decides when motion break-up is beneficial
• Calculates new feedrates based on cutting conditions encountered
• Creates a new optimized NC Program (Gcode or CLDATA)
How OptiPath Works
How OptiPath Works
• Constant chip thickness and load extends tool wear and cutter life• Can take deeper cuts-remove more volume• Use more of the cutter = longer tool life High Efficiency milling• Smoother operation and less stress on CNC machine• Better utilization of current CNC equipment = increased capacity
Benefits beyond time savings
How OptiPath Works
• Status window (configurable)
• Graphs window (configurable) hover mouse over graph to display data
“Helpers” for Optimization
Methods of Optimization
Air Cuts Only – Increase feedrates when the tool is not in contact with material (cutting in air)
– No risk of changing cuts or machined finishes on part
OptiPath – Optimization based on Chip Load and Volume Removal, or both
– Relies on User knowledge of Material type and Cutting capabilities
– Easily manipulated with settings and limits
Force– Optimization based on optimal Chip Load, and considering Force or Power limits
– Relies on cutter-to-material “characterization” data obtained via dyno-testing
– Physics-based force calculations, also takes into account cutter rake and helix angles
Force Optimization
1. MATERIAL HARDNESS
Find the SFM range
2. CUTTING TOOL
Find the Chip Load range
3. CNC MACHINE LimitsHP, Torque, Max fpm, Max rpm
4. CNC PROGRAM
RPM (spindle speed)
FPM (feed rate)
CLASSIC MACHINING FORMULAS:
Feed per Tooth: IPT= IPM ÷ Z ÷ RPM Cutting Speed: SFM= D x 0.26 x RPMSpindle Speed: RPM = SFM x 3.82 ÷ D Inch (Feed) per Revolution: IPR (FR) = IPM ÷ RPMTable Feed: IPM= IPT x Z x RPM Metal Removal Cubic IPM: MR= IPM x RDC x ADC
Cutting Physics made Easy!
Force Optimization
• Maintains ideal chip thickness
• Limits forces on cutting tools, or spindle power
• Creates optimized NC programs that run as fast and efficiently as possible, without risk of tool breakage or spindle overload
Great for hard or difficult to cut materials!
How Force Works
PHYSICSBased
• Physics-based optimization uses dyno-tested data to know how the cutter will react in material
• Calculated force and chip thickness results are used to adjust NC program feedrates, so chip thickness will as close to “ideal” as possible, while not exceeding user-specified limits
Why is Chip Thickness important?
"Maximum chip thickness is the most important parameter for achieving a productive and reliable milling process.”
"Effective cutting can only take place when maximum chip thickness is maintained at a value correctly matched to the milling cutter in use.”
“A thin chip... is the most common cause of poor performance resulting in low productivity. This can negatively affect tool life and chip formation. A value that is too high will overload the cutting edge, which can often lead to breakage.”
Force Optimization Process
1. Gather Force Material data– Cutting tests conducted on specific stock
material, with specific cutting tools, to gather data on cutting forces
– Known as Force Material “characterization”
– Force Materials data used to create Force Material (.vcfm) files for VERICUT
1. Gather Force Material data
2. Supply Cutter information
– Cutter Material
– Edge Type: Straight or Serrated
– Helix Angle
– Radial Rake Angle
Force Optimization Process
1. Gather Force Material data2. Supply Cutter information3. Analyze current cutting behavior (Force
“Analysis” mode)– Interactive with mouse- Data Display
panel shows wealth of information
– Note values when program runs well
– Charts “Followers” show where you are in the cutting process
– “Spikes” reveal potentially severe or dangerous cutting conditions
– Integrated with NC Program Review
Force Optimization Process
1. Gather Force Material data
2. Supply Cutter information
3. Analyze current cutting behavior (Force “Analysis” mode)
4. Enter Tool Force Data settings for ideal Chip Thickness, and limits for max Force/Spindle Power, and max Feedrate
Force Optimization Process
1. Gather Force Material data
2. Supply Cutter information
3. Analyze current cutting behavior (Force “Analysis” mode)
4. Enter Tool Force Data settings for ideal Chip Thickness, and limits for max Force/Spindle Power, and max Feedrate
5. Run Force optimization
Force Optimization Process
• Force charts compare original vs optimized NC program data
• Blue graph- Original program
• Red graph- Optimized program
• Red dashed lines- Limits set by user
• Green fill areas- where Force increased chip thickness (= savings)
• Red fill area- potential tool overload condition avoided by Force
Force Optimization Process
“Intelligent” Cutting Tools
• Some tooling vendors and cloud-based distributors include performance values with tool downloads
• Imported cutting tools with performance parameters speed optimization setup
• Mfr recommended values are not always “optimal”
What about Additive Manufacturing?
Machines with Additive capabilities
Big Area Additive Machines
• X
Additive adds Challenges• High-speed multi-axis machines with high-
power lasers = Safety concerns• Powdered metals consistency of• AM machine functions to keep track of:
– Power/Laser: On/Off/Power wattage– Material feed: On/Off/Flow rate– Shielding gas: On/Off– Machine feed: corresponds to material feed
• Adding material (without leaving “Voids”)• Subtracting material• More adding, more subtracting… Keeping
track of current part “build” state
• New $$$ Additive/Hybrid machine
• New manufacturing methods
• New CAM system and programming methods
• New post-processor…
What could possibly go wrong?
VERICUT Usage Flow
AUTO-DIFFAdditive Mfg.
OptiPath/Force
Grinder-Dressing
Optimization
Data
Optimized
Toolpath
CAD/CAM
Interfaces
CA
D/C
AM
Syste
m(s
)
Tooling
Interfaces
& Import
Tool M
gm
tS
yste
m(s
)
3D Models
Fixtures
Design
Machin
e S
hop
Control
Machine
Kinematics
Cutting
Tools
Toolpath
Reports
Screen Display
Stock
• Variables, Subprograms,
Macros
• Subroutines, Looping
and branching log
• Multiple synchronized
CNC controls
• Look-ahead or 3D cutter
compensation
• Tool tip programming &
tool length compensation
• Gage length reference
point programming
• Canned cycles and
fixture offsets
• Rotary axis pivot points
• Auxiliary mechanisms
• Force material
characterizations
• Known good cutting
conditions
• Data gathered from
learn mode
• Log file
• X-caliper results
• AUTO-DIFF report
• Tooling report
• Optimization results
• Inspection sequence
• Setup plan
• Reviewer (PC or iPad)
• Transfer from CAM
• Transfer from Tool
Management interface
• Download from “Cloud”
• Request from tool manuf.
• Model in CAD
• Model in VERICUT
• Obtain from MTB
• Obtain from CGTech
• Model from 2D drawings
• Measure machine
• Custom configuration made by CGTech
• Template VMC provided as-is
• Library VMC included with VERICUT
VERICUT Machine
Configuration (VMC)
Force
Calibration
Additive Mfg.
Checklist for Additive Simulation Ability to Add, Cut, Add, Cut… in any order
Simulate same NC code that will drive the machine
Collision checking for machine and AM components
Verify important AM functions & parameters• Laser activity, power
• Material feed, flow rate
• Shielding gas activity
Combine Additive-Hybrid-Conventional machining setups in any order (verify the entire process)
Didn’t expect that!
54
Mismatch on inside wall Rotary tables went “Home” before tool did
Cladding in wrong location (subtractive didn’t clean up)
“Additive Build Model” Table setup won’t work
Verify the manufacturing process end-to-end
VERICUT Usage Flow
AUTO-DIFFAdditive Mfg.
OptiPath/Force
Grinder-Dressing
Optimization
Data
Optimized
Toolpath
CAD/CAM
Interfaces
CA
D/C
AM
Syste
m(s
)
Tooling
Interfaces
& Import
Tool M
gm
tS
yste
m(s
)
3D Models
Fixtures
Design
Machin
e S
hop
Control
Machine
Kinematics
Cutting
Tools
Toolpath
Reports
Screen Display
Stock
• Variables, Subprograms,
Macros
• Subroutines, Looping
and branching log
• Multiple synchronized
CNC controls
• Look-ahead or 3D cutter
compensation
• Tool tip programming &
tool length compensation
• Gage length reference
point programming
• Canned cycles and
fixture offsets
• Rotary axis pivot points
• Auxiliary mechanisms
• Force material
characterizations
• Known good cutting
conditions
• Data gathered from
learn mode
• Log file
• X-caliper results
• AUTO-DIFF report
• Tooling report
• Optimization results
• Inspection sequence
• Setup plan
• Reviewer (PC or iPad)
• Transfer from CAM
• Transfer from Tool
Management interface
• Download from “Cloud”
• Request from tool manuf.
• Model in CAD
• Model in VERICUT
• Obtain from MTB
• Obtain from CGTech
• Model from 2D drawings
• Measure machine
• Custom configuration made by CGTech
• Template VMC provided as-is
• Library VMC included with VERICUT
VERICUT Machine
Configuration (VMC)
Force
Calibration
Reports
Automated Reports
• Additive usually requires less material• Additive can make inexpensive tooling• Additive processes are typically slower
than subtractive processes• Additive equipment is often limited
• When more strategies are available, simulation and reports help you make informed decisions about which process plan is “optimal”
Free 3D Reviewer
• Windows PCs or tablets, iPad tablets• Capture the entire part manufacturing
process (all operations) so it can be reviewed by anyone
• NC Programmers save Review file after verification/optimization
• Operators and shop personnel preview setups and tool sequences
• QA and others can quickly identify source of non-conforming part features
• Share between departments, or shops