We are a software component provider for the CAD/CAM industry. Our expertise in 5-Axis simultaneous machining and Simulation is recognised throughout the CAM industry and its software components and development services are used by the majority of the leading CAM vendors. Our 5-Axis and Simulation software has been used in the manufacture of complex parts for over a decade and we have many 1000’s of users in the global CAD/CAM industry.
Saturday, June 2, 2012
Newsletter, courtesy of partner MAL and distibutor Terranic Systems
The newsletter below is re-produced courtesy of our partner MAL, whose product is distributed by Terranic Systems Inc. More information is available on the website, and they also have an good blog. This article gives more information on blade machining. Note, some of the formatting has defied blogger's authoring software and as hard as I try, some of the text has escaped the main frame.
The ModuleWorks Blogger.
SYSTEMS | MAL INC
Steam turbines are jewels of power generation industry.
According to Wikipedia, they alone constitute about 90% of all electricity
generation in the Unites States. Steam turbines extract energy from high
pressure, high temperature steam via blades attached to a rotor.
Blade geometry is a major factor in turbine's performance.
Its intricate design improves energy generation making turbines more
efficient and productive. In today's digital age, design engineers utilize
various tools to improve blade shapes, which are now even more difficult to
be produced with required specs.
Sandvik Coromant's application development team develops
know-how in tackling difficult production tasks like blade machining. The
team combines their expertise in machining with the latest digital
tools to come up with
best practice guidelines. Every aspect of machining - from fixture design
to tooling and tool path strategies - is meticulously analyzed, compared,
tested and proven before implemented at a customer site.
Striving to achieve the best process possible, the team
worked with us to utilizeMACHpro
Virtual Machiningsoftware (demo
video), which was set up tokeep
consistent chip load without overstressing cutting tool or machine.
Original5-axis NC programwas thenautomatically
optimization module. After two attempts, the team accomplished anoverall productivity increase
of 57%(three roughing,
two semi-finishing operations combined)
MACHpro'sautomatic feed optimization
eliminated inefficient feed ratesalong
5-axis tool path where cut geometry greatly varied. The original NC program
used one feed value, which was good for the heaviest cut, throughout entire
operation. However, MACHpro's intelligent feed optimizer wasable to calculate exact load on
the tool at any point along the tool path, hence successfully varied
the feed rate to boost material removal rates while avoiding tool overloads.
Two snapshots given below show howMACHpro adapts feeds based on
varying tool load along the path during roughing.
Problem - Tool is overloaded.
Remedy - Feed is reduced from 2674 to 2458 mm/min.
Outcome - Tool and spindle overloads are prevented; insert life is
prolonged. Right Photo
Problem - Tool is lightly loaded, under-utilized. Problem - Tool is lightly
Remedy - Feed is increased by about 300%.
Outcome - Tool and machine are fully utilized without overstressing any
component; insert life is maintained.