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#1 2015-01-31 00:28:09

vhubbard
Beta User
From: Dallas, TX
Registered: 2004-11-11
Posts: 220
Website

Min Ramp angle and max plunge distance setting needed for cutters.

On many high speed machines plunging too deep or  ramping at too much of an angle adds pressure in Z and many spindles can be damaged.   Example, we have 1.5" insert mills that if you plunge more than .15 you run out of cutting on the inside of the cutter.  Also ramping at an angle greater than the tool was designed for can break a tool or cause premature failure. 

Traditionally the answer given by CGTech to correct this problem was to add a holder cylinder in the end of the tool. At a distance equivalent to the ramp angle the tool is capable of.   This can significantly slows down the simulation.   Once the
holder on the end of the tool enters the stock volume or fixture volume collision check box, it goes into fine collision checking.   This can slow a job with 100 thousand or more moves significantly.

Vericut needs the option to define a max Ramp angle and max plunge depth for a milling cutter.   If the move ramps too much in relation to the tool axis, a warning should be given.   

This could also be a big step in finding tool wear problems in Vericut for all machines, not just high speed machines.  Too much ramp or even plunging with a non center cutting tool should be caught without the heavy overhead of collision checking.

ER has been submitted.  Pile on with your own ER request if you like this.

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#2 2015-01-31 19:45:04

DaveF
Senior Member
From: Valencia, CA
Registered: 2005-08-20
Posts: 304

Re: Min Ramp angle and max plunge distance setting needed for cutters.

Hi Val,

This topic is part of the Top Ten Catia enhacments I have written for the COE annual conference.

A subset of other "improper methods detection"...
*  conventional, straight down at any feed.....
*  changing tool axis at high speed while too close to the part.
*  Imagine a 400 IPM 3d move that missed the part by .03.  How do you find that?    Machine lag and the tool hit the part.  I say ...hit, because it happened.

One solution is .. grow the cutter like CGG at high speeds, and detect.

I was about to add this request myself, but I was focused on ER's for graphs.  If you post the ER #, I'll add Aerospace Dynamics International to your request.



Best Regards
Dave Frank


Dave Frank
Aerospace Dynamics International, PCC
Valencia Ca
"Where else can you have this much fun,.......and get paid???."

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#3 2015-02-02 16:40:34

vhubbard
Beta User
From: Dallas, TX
Registered: 2004-11-11
Posts: 220
Website

Re: Min Ramp angle and max plunge distance setting needed for cutters.

SCR #13938 -- enable a checking option on minimum ramp angle for mill tool

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#4 2016-01-05 23:24:59

DaveF
Senior Member
From: Valencia, CA
Registered: 2005-08-20
Posts: 304

Re: Min Ramp angle and max plunge distance setting needed for cutters.

Hi Val,

We piled on, and issued a “Me Too” on this ER to CGTech…. After experiencing  “The China Syndrome”  a few months ago.  For those that did not see the movie  “The China Syndrome”  it refers to metal burning up and melting thru.  Only a tool, not a nuclear reactor like the movie. 
.
We would like to see a  [  ] radio button on the tool, ramping permitted … Yes / No in addition to the max ramp angle.  I suppose max ramp angle = 0 works also.
.
The holder cylinder in the end of the tool.. is a somewhat acceptable  work around with the issues of performance you mention. Pretty creative for the 1st guy that thunk that one up. It is definitely using a screw driver as a hammer.
.
Another place to do this check for this in the postprocessor. For each move look at /  calculate the angle between the tool axis vector and the forward vector. (forward vector= current position, to next position)  It should be 90 Degrees. Anything greater than 90 is the ramp angle. 
.
Best Regards
Dave


Dave Frank
Aerospace Dynamics International, PCC
Valencia Ca
"Where else can you have this much fun,.......and get paid???."

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