Introducing 3 Axis Adaptive Roughing!

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MecSoft is proud to introduce the latest addition to its 3 Axis advanced machining suite, 3 Axis Adaptive Roughing. This advanced 3 Axis method can be added, as a separately priced module, onto any configuration starting with Standard (STD). That’s right, you don’t need to have the Expert, Professional or Premium configuration to get the benefits of 3 Axis Adaptive Roughing!

What is Adaptive Roughing? 

The Adaptive Roughing operation is a high speed bulk material removal toolpath method characterized by its tangential cut (i.e., constant cutter engagement) pattern. It reduces tool pressure and keeps chip load more consistent. It is especially valuable when cutting harder materials and generally results in much better tool life. Similar to Horizontal Roughing material is removed in layers or levels from the raw stock model. This is a constant contact toolpath method with just one entry and on exit at each cut level. Typical tools used for this kind of operation are Flat or Corner Radius mills. 

Key Benefits

3 Axis Adaptive Roughing offers the following key benefits not found on other 3 Axis roughing toolpath methods.

  • Consistent Cutting Conditions: With Adaptive Roughing there is only one entry and one exit for each cut level. You can also choose between Climb (down cut) or Conventional (up cut) meaning that the cutting condition of the tool remains consistent from start to finish for each cut level.
  • Increased Material Removal Rates: This method employs a High-Speed tangential cut pattern that facilitates the use of higher cut feed rates, making material removal fast and efficient. 
  • Reduced Cycle Times: The consistent cutting conditions and increased cut deed rates of the toolpath strategy results in much shorter cycle times even when more material needs to be removed.
  • Extended Tool Life: When combined, these benefits result in longer tool life so you will see a reduction in the purchasing in replacement tools. 
  • Reduced Stress on Machine Tool: In addition to longer tool life, this toolpath reduces rapid acceleration and deceleration in your machine tool, thereby increasing machining accuracy over the long run as reducing maintenance costs. 

 

Key Features

A wide range of features have been combined to make the 3 Axis Adaptive Roughing one of the smartest toolpath strategies in the MecSoft suite. The illustration below highlights these features on a sample part. Each feature is also illustrated below. 

Smart! Adapts to Part Features and Stock Conditions

Intelligence is designed into this Adaptive Roughing method. Your stock parameters and part features are analyzed and an adaptive roughing toolpath is generated to meet your specific needs. 

Smart! Adapts to Part Features and Stock Conditions

 

Spiral Engagements to Maximum Pocket Width

The maximum width of each pocket feature is calculated and a spiral path is employed. When this spiral path becomes constricted high speed tangential motions are added to maintain consistent cutting conditions. 

Spiral Engagements to Maximum Pocket Width

 

Corner Machining with Minimum Engagement Radius

When a corner feature is encountered a minimum engagement radius is calculated maintaining cut feed rate and minimizing cycle time.

Corner Machining with Minimum Engagement Radius

 

High Speed Cuts along Stock for Short Transfers

When short cut transfers are needed, the cutter will traverse along the stock perimeters at the cut feed rate minimizing cycle time even further. 

High Speed Cuts along Stock for Short Transfers

 

Adaptive Rest Machining between Levels

3 Axis Adaptive Roughing employs adaptive rest machining between levels. If stock remains on any portion of the part additional cut levels are added to remove it.

Adaptive Rest Machining between Levels

 

Step Minimization on Slopes and Contours

When Adaptive Roughing encounters a contour, Step Minimization is employed to further remove stock material. For example if the distance between cut levels is 50% of the cutting tool diameter, you can specify a lower cut level of say 25% that will automatically be employed along slopes and contours keeping the remaining in process stock to a minimum.

Step Minimization on Slopes and Contours

 

Cut Depths to Full Flute Length

In Adaptive Roughing the cutting tool will cut to it’s full flute length maximizing cutting levels and material removal.

Cut Depths to Full Flute Length

 

Depth/Level First Z Level Ordering

3 Axis Adaptive Roughing also employs Z Level ordering that allows you to control how cut levels are removed. Depth First will remove each pocket to its full depth before transferring to the next cut level. Level First will clear the entire level before moving to the next level.
Click here to enjoy the complete cut material simulation of this part.

Depth/Level First Z Level Ordering

 

How to Get 3 Axis Adaptive Roughing

3 Axis Adaptive Roughing can be added to any of the following MecSoft CAM configurations: Standard, Expert, Professional and Premium for VisualCAD/CAM, RhinoCAM or VisualCAM for SOLIDWORKS. Contact our sales team (949) 654-8163 Option 1 today to get 3 Axis Adaptive Roughing. 

3 Axis Adaptive Roughing Cut Material Simulation

 

More Information

For more information about each of the Mill Module products, including data sheets, videos and other resources we invite you to visit the following product pages:

 

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Don LaCourse

Don LaCourse

Don LaCourse is an Application Engineer with MecSoft Corporation. Don brings over 20 years of experience in CAD/CAM operations in both automotive and mold design applications. Don also has extensive experience in documenting CAD/CAM products and is actively involved with writing the on-line help as well as creating training tutorials for MecSoft's products.

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