Ultra-precision machining is used for parts that need to be machined to an accuracy of just a few micron and a roughness in the range of nanometres. Optical parts require both types of machining, ultra-precision machining for the optically effective areas of the part and conventional machining for the non-optical areas. ModuleWorks has developed CAM software components that enabled Zeiss to combine both types of machining in a single, integrated solution.
Integrating all machining relevant processes in a unified system accelerates process programming for cutting complex freeform surfaces and improves the quality and cost-efficiency of producing ultra-precision optical parts.
Offering 6-axis control, the new software is powered by the ModuleWorks 64-bit ultra-precision kernel. The kernel is based on the industry-proven ModuleWorks 5-axis technology for toolpath generation and has been specially developed to meet the growing demand for high precision machining of increasingly complex geometries in the optics industry.
The ModuleWorks ultra-precision kernel supports point clouds, NURBS surfaces and parametric geometries and uses multi-threading for fast toolpath generation with radial, spiral and parallel patterns for slow and fast tool kinematics. The freely configurable machine model supports all machine tool types for grinding and diamond turning applications as well as grinding patterns for roughing, drilling, chamfering, slotting and contouring. Full 3D machine and material removal simulation software can also be applied with the high resolution of ultra-precision machining requirements. The high performance CNC posting framework provides scriptable CNC data output at a rate of 50K points per second and supports multi-threaded cloud posting.
The software is the result of research and development projects between Zeiss, ModuleWorks and Fraunhofer IPT. It was presented at the Euspen 2018 International Conference & Exhibition (4-8 June) in Venice and is available now as a software library that can be integrated into existing CADCAM systems. A full demonstration version is currently being implemented in the ModuleWorks Rhino CAM plugin.
