New toolpath strategy from Delcam slashes machining times by up to 60%

Vortex, for which Delcam has a patent pending, has been developed to gain maximum benefit from solid carbide tooling, in particular, those designs that can give deeper cuts by using the full flute length as the cutting surface. It can be used for 2 and 3-axis roughing, positional 5-axis area clearance and for rest machining, based on stock models or reference toolpaths. Unlike other high speed roughing techniques that aim to maintain a constant theoretical metal-removal rate, the Vortex strategy produces toolpaths with a controlled engagement angle for the complete operation. This maintains the optimum cutting conditions for the entire toolpath that would normally be possible only for the straight-line moves. As a result, the cutting time will be shorter, while cutting will be undertaken at a more consistent volume-removal rate and feed rate, so protecting the machine. Initial tests have shown that Vortex and Machine DNA will save up to 60% in machining time, based on the trial shown in this video, which compares the Vortex strategy against the optimum use of the existing conventional High Feed Roughing strategies currently available in PowerMILL. "Anyone using the Vortex strategy will be able to hear the difference immediately," claimed Mark Forth, product manager for Delcam's Advanced Manufacturing Solutions. "Conventional roughing produces a sound of varying pitch, which indicates tool overload and chatter, while Vortex roughing gives a constant pitch showing that the tool is operating under consistent conditions. Users will also be able to see the difference in the regular size and thickness of the chips produced, providing further evidence of the consistency of the cut."