The application of CimatronE in high speed machini

CimatronE programming features in cavity mold high-speed machining

due to the rapid development and promotion of mold manufacturing industry, the market competition is increasingly fierce, the requirements of mold accuracy are higher and higher, the requirements of manufacturing cycle are shorter and shorter, and the manufacturing cost is also required to be reduced to the lowest. Therefore, for each mold manufacturer, it is necessary to adopt the current advanced manufacturing methods, equipment and high-quality talents. In mold CNC processing, high-speed machining is one of the advanced and practical processing technologies, which has been widely used in the mold industry

high speed machining is cutting at high speed, high feed and low load. The material removal rate per unit time is very high. Due to the small cutting amount and cutting force, the deformation and vibration of the tool are reduced. When cutting, iron filings will take away most of the cutting heat, so the thermal deformation of the workpiece is less, and the processed mold has high precision and good finish. On the other hand, because it is impossible to stop the machine tool at any time in the process of high-speed machining, it is necessary to have a very high security strategy and stable and rich machining strategy for the programmed CAM software

1. rough machining

first establish the cube blank of the machining object and the part program consistent with the mold surface, so that the system will refer to the blank information at any time when calculating the tool path to ensure the accuracy and safety of the tool path

rough machining adopts the processing method of rough spiral, without specifying the processing depth of the highest point and the lowest point, and automatically adopts the strategy of horizontal layering and layer by layer cutting based on the initial blank shape

the internal rapid tool lifting height is in an incremental manner, and the fillet connection can be set to ensure the smooth transition of the path when the machine tool moves rapidly, so as to avoid the machine tool jitter caused by sharp corners

the feeding mode adopts the optimization mode, and the industry concentration under the deep spiral is low. These problem cutters are truly surrounded between layers, and the entry beyond boundary/stock limits are set. The system automatically recognizes the external feeding of the blank in the open area, the spiral feeding or diagonal feeding in the closed area, and the minimum feeding size can also be set to avoid the top cutter, so as to achieve the cutting filtering of small areas

in addition to forward milling and reverse milling, the milling direction also has the mode of "mixed milling + final forward milling/reverse milling", which can not only reduce tool jumping, but also ensure the use of forward milling or reverse milling when approaching the last tool of the workpiece

the locally amplified cutting depth is optimized to ensure that the machining allowance of each table surface at different depths in the mold cavity is within the predetermined range

cavity mold adopts the trochoidal method, which can effectively avoid full tool cutting, facilitate the rapid removal of iron filings, and extend the tool life

in any case, the automatic fillet transition of the tool path corner can prevent the sharp turning of the tool path path and avoid speed loss and machine tool vibration

in addition, the optimization of various feed rates is also very rich, such as: plung feed, entyr feed, and adaptive feed control of corners. For finish machining, there are also: side feed and down feed. The rough machining tool path is shown in Figure 1-2

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Figure 1 rough machining front view

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during rough machining, in order to efficiently start, click to rotate and drive the turbine reducer to remove materials in motion, the tool diameters used are relatively large, and there are still a lot of residual materials in some positions of the cavity due to the influence of the tool. Cimatron E's secondary rough machining method (rerough) is designed for this purpose

rerough intelligently identifies the remaining blanks of the previous program, and only needs to select a tool with relatively less rough machining, which can automatically generate the rough machining path of scrap

because the processing parameters in Cimatron can be set to the form of related variables, such as the tool spacing is set to "0.40*tldi", and the minimum cutting size is set to "tldi-3*crrd", where tldi represents the tool diameter. As for motion parameters, rotation speed, feed rate, etc., they can also be called directly from the preset tool magazine, so only a few parameters need to be adjusted for secondary rough machining, and other settings are basically the same as those of rough spiral

at the corner of the mold, the step of the non planar tool path or the position where the front tool can not be milled, and the position where the current tool can be milled is automatically generated, which is mainly used for the continuous production of a large number of products with the same section, single tool or multi tool path, and the hypocycloid machining can be reasonably used, as shown in Figure 3. After one or more times of secondary rough machining procedures, a cutting environment with basically uniform allowance is provided for semi finish machining

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Figure 3 secondary rough machining

3. Semi finish machining and finish machining

cimatron e have a variety of finish machining methods, including both high-speed machining and traditional machining methods