optimize parts machining with nx cam milling operations · optimize parts machining with nx cam...

Optimize parts machining with

NX CAM Milling operationsAlexander Freund – Lead Product Manager Mold&Die

Realize innovation.Unrestricted © Siemens AG 2018

Unrestricted © Siemens AG 2018

Siemens PLM Software

Content

• Adaptive Milling

• Surface Contour

• Guiding Curves

• Usability



Adaptive Milling

- Live Milling Test

NX12.0



Adaptive Milling

Bottom Up Cutting

Capability

• Adds intermediate cut levels to the Adaptive Milling

tool path, starting from the main level working its

way upwards.

Customer Benefits

• Ensures consistent and evenly distributed stock on

tapered and contoured walls.

• Especially useful on Mold inserts

NX1847



After 1st cut level Bottom Up Cutting

after 1st cut level

After 2nd cut level Bottom Up Cutting

after 2nd cut level

Adaptive Milling

Bottom Up Cutting

NX1847



Adaptive Milling

Minimum Cut Depth

Capabilities

• Sets a Minimum Cut Depth for the Flute length in

use

• Secures a minimal amount of contact points of the

flute in use

Customer Benefits

• Stabilized Cutting Process

• Increased Tool Life

• Process safety

NX1847.



Adaptive Milling

Minimum Cut Depth - Video

NX1847



Adaptive Milling

- Bottom Up Cutting Live

Machine DMC 80U

Material: 1.2379

DIN: X153CrMoV12

Type: Cold Work Steel

Hardness: Hardened - 60 HRC



Adaptive Milling

- Bottom Up Cutting Live

Tool: Fraisa HX-NVS

D1 [mm] 20

z 4

vc [m/min] 110

fz [mm] 0.276

ap [mm] 38

ae [mm] 0,3

n [1/min] 1750

vf [mm/min] 1935

Q [cm3/min] 29,4

../Enablement/NX1202_Enablement_3_Axis_Milling/Videos/DMG_Machine_tests/2996.mp4

../Enablement/NX1202_Enablement_3_Axis_Milling/Videos/DMG_Machine_tests/2996.mp4



Adaptive Milling

Custom Feed & Speed

Capabilities

• Set custom Feed & Speed for Helical Engage

motions, when using Adaptive Milling.

• Set dwell time when the Helical Engage starts and

ends

• Can be found in the Closed Area Engage Group in

the NCM Dialogue

• Is only visible if you turn the option ON

• Available for Cavity Mill, Floor Wall and Planar Mill

in NX1847

Customer Benefits

• Allows for larger ramp angles on modern machine

tools

• Utilizing high efficiency cutter tools better

• Savings in machining time

NX12.0.2



Adaptive Milling

Custom Feed & Speed – Comparison NX Simulation Video

NX12.0.2



Adaptive Milling

Custom Feed & Speed – Comparison Live Video

NX12.0.2



Adaptive Milling

Pillar Cutting

Capabilities

• Automatically detects, if a small pillar is left during

the Spiral Facing in Adaptive Milling

• Leaves a cylindrical geometry which is milled with

Helical Motion

• Custom Feeds and Speeds and the Ramp Angle

from the Helical Engage settings in the NCM

dialogue will be applied to the Pillar Cutting

Customer Benefits

• Increased Tool Life – especially in hard materials

like Inconel or Titanium

• Higher Process safety

NX12.0.2



Adaptive Milling

Pillar Cutting - Video

NX12.0.2



Capabilities

• The coolant type can be defined separate for Open

and Closed Area Regions

Customer Benefits

• Optimized chip evacuation

• Extended tool life

• Enhanced Process safety

• Faster Programming time

Adaptive Milling

Open and Closed Area Region Coolant

NX1847



Adaptive Milling

Minimum Curvature Radius

Capability

• By increasing this value, the amount of cuts in the

corners are reduced

• Avoids short cutting moves in corners

Customer Benefits

• Reduces tool wear

• Decreases Machining Time

Minimum Curvature

Radius=2

Minimum Curvature

Radius=0

NX12.0.2



Complex Machining

- 5-Axis Adaptive Milling

Early Prototype



Content


• Surface Contour

• Guiding Curves

• Usability



Area Milling

Zlevel Helical Cut Pattern

Capabilities

• Helical cut pattern for steep regions in Area Milling

• Start and Finish passes automatically added

Customer Benefit

• Improve efficiency with reduced Engages/Retracts

NX12.0.2



Zlevel with Ramp on Shape Contour Area Steep Helical

Area Milling


NX12.0.2



Area Milling


NX12.0.2



Area Milling

Spiral cut pattern

Capabilities

• Cut pattern which offsets from sub region

boundaries defined in Cut Region Manager

• Continuous tool path with 3D constant pitch

between passes with minimum Engage and Retract

motions

• Especially useful for symmetrical part geometries

Customer Benefits

• Improves efficiency and surface quality with reduced

Engages/Retracts.

NX12.0.2



Area Milling

Spiral - Video

NX12.0.2



• None: Finishing Passes will not be added

to either inner or outer boundaries.

• Outer Shapes: Finishing Passes will be

added to outer boundaries only.

• Inner Shapes: Finishing Passes will be

added to inner boundaries only.

• All Shapes: Finishing Passes will be

added to both inner and outer boundaries.

Area Milling

Spiral cut pattern

None Shapes Outer Shapes

Inner Shapes All Shapes

NX12.0.2



Capability

• Enhanced algorithm to create on part stepover

toolpath

Customer Benefit

• Superior productivity due to improved performance

of toolpath generation

Area Mill On Part

Overview

NX12.0.2

Performance comparison:

• 450 test operations used.

• Average performance gain of 30~50%

• Performance gains of up to 90% seen.



Surface Contour

Corner Smoothing – On Part

Capabilities

• Available in Guiding Curves and all Area Mill Non

Steep Patterns

• Smoothens the corners in toolpaths with the

Stepover Applied On Part

Customer Benefits

• Smooth toolpath

• Better surface quality

NX12.0.2



On Part Path Smoothing

Path Smoothing - OnPath Smoothing - Off

NX12.0.2



Content


• Surface Contour

• Guiding Curves

• Usability



Guiding Curves

Overview

Capabilities

• Guiding Curves is a surface milling operation where

the pattern is driven by one or two sets of curves

(Guides)

• “Morphing” – the pattern is evenly interpolated

between the two guides

• “Constant Offset” - offsets the guide with

Constant stepovers

• Pattern is highly controlled by the user. He can drive

the pattern to follow his intent

Customer Benefits

• Smooth toolpath

• Better surface quality

NX12.0.2



Guiding Curves

Constant Offset - Video

NX12.0.2



Guiding Curves

Morphing- Video

NX12.0.2



Guiding Curves

Racetrack around Guide and Defined Area - Video

NX12.0.2



Content


• Surface Contour

• Guiding Curves

• Usability



Adaptive Milling, Cavity Milling, Z-Level

Cut Depth with % of the Flute Length

Capabilities

• It is now possible to set a % of

the Flute Length for the Cut

Depth, the Step Up Distance and

the Minimum Cut Depth

Customer Benefits

• Saving of programming time

• Process safety when doing a tool

change

NX12.0.2



Merge Path By Contour Count / Concatenation

Why

• Attempting to satisfy complex specific rules in a native

operation highly mess the UX

• Competition has merging and editing capabilities uses as part

of the base workflow

What

Merge 2 or more operations

Merging rule – by Contours count

Lag to satisfy shift of the count for the first set

Merge into one “level” (?)

1

2

3

4

5

6

8

7



Tangent Barrel Tool for Blade Finish

• Reduced machining time through utilizing bigger tool radius

• NX supports Barrel mill for blade finish and Variable contour

operations

• A new Tool Type was created to ease the definition – Tangent Barrel

Alexander FreundLead Product Manager Mold & Die

Siemens Industry Software GmbH

[email protected]

Thank you.

optimize parts machining with nx cam milling operations · optimize parts machining with nx cam...

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