Over 20 visitors from leading advanced manufacturing and technology companies based in the Netherlands and Belgium saw how cycle times could be reduced via a demonstration of the physics-based optimisation technology.
Force determines the maximum reliable feed rate for a given cutting condition, based on four factors - force on the cutter, spindle power, maximum chip thickness and maximum allowable feed rate. It calculates ideal feed rates by analysing tool geometry and parameters, material properties of the stock and cutting tool, detailed cutting tool edge geometry and, of course, Vericut cut-by-cut contact conditions.
Says Gerard van Kessel, sr. application engineer, Van Hoorn Carbide: “At Van Hoorn Carbide, we are always looking for technical ways to improve production processes and save money for our customers. With Vericut Force it is possible to improve the efficiency, speed, or both, of your process. We measured forces like bending moment, torsion and pulling forces, and were able to significantly reduce peaks, or bending moment forces, even with a shorter cycle time. In the areas with lower forces during the process, the software increased the feed until a fixed average chip thickness was achieved, and in the areas where the forces were considerably higher, such as corners, the software decreased the feed. Giving us a more stable, efficient and faster cycle. VERICUT Force is a really productive innovation in the world of manufacturing and we will be recommending it to customers to optimise production processes.”
A hinge bracket demonstration piece created by CGTech’s Netherlands reseller ATS EdgeIT reflected the typical challenges faced by Dutch manufacturing companies, with a range of machining operations such as profile milling, pocketing, 3+2 axis-milling, 5-axis simultaneous flank milling and deburring from a solid blank of stainless steel.
A selection of Van Hoorn’s solid carbide tools were chosen and, with guidance from Van Hoorn’s application specialists, the optimal cutting rates were dialled in to give a good machining process. Force was then used to reduce machining time by a further 16%, whilst stabilising the cutting conditions, improving surface finish and extending tool life. The machining process was audibly calmer, yet faster. The benefits of the Force optimisation were further underlined by the use of a Pro-micron SPIKE sensory tool holder to measure the forces at the cutter.
Country sales manager Lee Fowkes concludes: “Force provides a ‘purple patch’ for companies using machine tools. It can increase the life expectancy of the cutting tools, improve the post-processed cutting toolpath from the CAM system, leading to shorter machining cycle times, look after the machine tool’s structural elements, as each cut is analysed the software minimises any ‘shock loads’ creating a smoother but quicker cutting cycle.”
