New Strategies for Machining Cycles, Tombstones and Additive Functions

Edgecam 2020.1 from Hexagon Manufacturing Intelligence (North Kingstown, RI) features toolpath associativity for the face mill cycle, an option to extend the parallel lace toolpath, enhanced additive undercutting and about 30 other updates, including an optional CAD for CAM Designer module that now replaces Part Modeler. From model design to part repair and modification, Edgecam Designer is ideal for taking geometry through to manufacture. More than 50 enhancements to Designer include the ability to attach finishing and tolerance information to models and faces with the new ‘surface attributes’ command. The software reads this information and applies it to the features for use in strategy decisions or to set speed and feed rates. A powerful new ‘edit boundary’ command can modify the trimming of faces directly on a sheet or solid body without having to extract any surfaces or edges. This new version also delivers a fresh look and feel for the ‘auto-constrained surface’ command that is used to quickly create complex surfaces.

Edgecam 2020.1 enhances the additive lace cycle’s ‘undercut’ function by allowing the user to set a maximum overhang angle. “This is necessary because different materials and processes require different negative material build-up depending on the target shape,” explained product manager John Buehler. “If the undercut angle is too big, it can be compensated for by using the maximum overhang angle, effectively over-ruling the angle on the part.” Further boundary control options have also been included that mimic the same functionality of other milling cycles, allowing for greater material displacement control. This latest release significantly enhances the existing chamfering cycle with five new pieces of functionality that are similar to those already found in the profiling cycle. Greater toolpath control is achieved with the new cut increment and Z-offset modifiers. Previously, if there were heavy cutting conditions, several chamfer cycles had to be created. Now users simply set a cut increment value that not only results in multiple toolpath passes, but also increases tool life.

Six ‘corner strategies’ now enable programmers to choose the type of external corner condition the cycle produces. This is particularly useful when a smoother corner blend is required. The introduction of ‘optimize path and lace bandwidth’ modifiers reduces cycle time by determining the order in which the cycle is deployed. “Toolpath associativity is a vital factor when programming production components, as CAD modifications can take considerable time,” said Buehler. “Edgecam 2020.1 removes such delays by making the face mill cycle sensitive to the stock model. When either the stock or component solid model are altered, the toolpath automatically adjusts both the X-Y and the Z height of the toolpath.” Also, the lead modifier now helps increase tool life with a ‘horizontal’ lead type that ‘rolls’ the cutter into the initial face of the material, reducing cutting forces. The ‘pre-finish plunge’ function in previous versions reduced cycle times but increased the potential for collisions where the stock was larger than the groove feature. This new release resolves that issue by introducing a ‘use current stock’ function to ensure the cycle always begins higher than the current stock.

The toolpath in the parallel lace cycle can now be extended. The function is similar to the one in the profiling cycle, which has been brought in following requests from users. The extensions follow the direction of the cut and are applied in the primary direction, ‘stretching’ the toolpath to guarantee better surface texture, an allows the cycle to cater for over-size stock. An enhancement to the existing ‘Swarf’ control command means a specific time period (in minutes) can be set for the turning insert to be in contact with the material. This is particularly useful when machining hard material where there’s a requirement to control the wear rate on the insert. “The tool will return to its retract position once the time period has been reached,” noted Buehler. “Edgecam will automatically put stop commands into the program, allowing the user to inspect the insert before continuing with the rest of the cut.”

The Tombstone Manager has evolved into a particularly powerful tool for production engineers working with multiple batch quantities. It introduces two significant enhancements controlling the deployment of each tool, with two new ‘priority’ functions: First, ‘by tool then by plane’ rationalizes by tool, followed by reducing indexes. Second, ‘by plane then by tool’ rationalizes by plane/datum before reducing tool changes. Anyone wanting to use part files with multiple machining sequences will see that the general performance of the tombstone software has improved and that sorting priorities have been enhanced. Edgecam 2020.1 now fully supports turrets with half positions, where the turret has numbered positions like a clock face with a further set between the main positions. Typically, a 24-station turret is numbered in this sequence: 1, 13, 2, 14, 3, 15, etc. The simulator now displays all the tooling in its correct relative positions, giving a realistic simulation. This can be particularly important when neighboring tools get close to the stock and part.

Hexagon Manufacturing Intelligence, 250 Circuit Drive, North Kingstown, RI 02852, 855-443-9638, Fax: 401-886-2727, www.hexagonmi.com.