The 5-axis roughing has been designed for a simple and fast roughing operation that removes the maximum amount of material in a single operation by utilising full 5-axis motion. There is a huge time saving on the operation when machining on non-linear areas.
Andrew Walters, application engineer from Tebis UK, commented “There is a huge time saving on the operation when machining non-linear areas. Traditionally roughing would employ small step-downs with a larger width of a cut calculated in a water-line fashion method. With Tebis, we will use a 5-axis simultaneous motion to allow us to get down into complex forms." As well as improving operational cycles, cutting tool life is also extended through greater efficiencies.
As well as an increase in tool life and operation accuracy by giving a more consistent volume of roughed material on a part, the finishing tools need to do less work. An additional benefit of this process is a more consistent volume of roughed material on a part.
5 Axis Radial Roughing for Mill/Turn all in one package
Tebis CAD/CAM is capable of utilising 5 axis adaptive roughing in a conventional milling environment, but it can also apply advanced 5 axis roughing strategies to mill/turn machines as well. By applying these operations in turn/mill processes, Tebis will maximise material removal and tool life whilst minimising the cut time.
Automation CAD/CAM Control Surface Creation
In most CAM system it is necessary to create a control surface when programming 5 axis machining operations. In Tebis CAD/CAM this function is automatic, with the control surface being created in the background by selecting only the surface you wish to machine. This will give a very accurate creation of vectors for controlling tool and head direction. There is no need to switch between CAD and CAM packages which saves time by not having to create the control surface data and also increase consistency and accuracy.
Tebis CAD/CAM software is capable of using template and automation in 5 axis which is able to give consistent toolpaths and cutting conditions by using standardised parameters. This way all output programs are using the same stepovers, lead ins/outs and safety clearances. Tebis offers reliable processes and make quality highly controllable and repeatable.
Virtual Machine Technology
Tebis software uses Virtual Technology at three stages of the process: planning, programming and verification.
The first stage is the planning process; the machine operator needs to know if a component which is planned to be machined will fit on the machine bed. This can be checked along with the optimum setup position for the tool tilt directions and check cutting tool lengths required. If this is not done like other systems, machine limits will most likely be hit.
For programming, Tebis CAD/CAM uses the Virtual Machine for calculation of toolpaths as it contains the machine rotational limits. It is possible to see when programming if a toolpath angle can be achieved on a 5-axis machine. Tebis will not allow creation of a toolpath which is not achievable in reality.
The last of the three stages is the process of verification, which is the toolpath checking. This prevents any collisions, not just against the cutting tool and a component, but the whole machine, its limits, shields, barriers, fixtures and any other component setup on the machine at the same time. If there is a problem, it is easy to modify and recheck during the programming process.
Andy also explains: “Other software companies are unable to check the connection between toolpaths. Once the toolpaths are completed, the machine takes over the control, rotates and repositions the tool correctly. Tebis software has the full control over the movements between the end and the beginning the next toolpath. These are fully programmed, controlled and fully verified in the Virtual Machining Technology”.