Smaller Tools Accomplish Larger Jobs – OptiRough for Mastercam
Old methods of roughing are becoming obsolete. The current, standard technique for roughing is to mill with one large cutter at shallow depths until you achieve the desired contoured pocket formation. The standard method works for larger areas of material that need to be cut away. However, the meticulous tool paths cannot be achieved by the same, large tool. Therefore, multiple tools need to be substituted to finish the job. Mastercam from CNC Software Inc. has innovated a new way with their X5 software release that makes this process more efficient, and it’s called OptiRough.
How is OptiRough different from standard roughing techniques?
Their new approach starts with a small tool to cut at a starting depth. The most innovative concept of this technique is that the entirety of the flute is used to cut (producing even wear on the entire tool). Essentially, the tool can make initial cuts at deeper depths using arching or circular formations; where standard roughing applies shallow depths. The arching formation is essential to the process by maintaining consistent tool engagement. This, primarily, is to avoid high load movements that can bury the cutter which often happens in corners. Optimizing the speed of chip formation and minimizing tool wear will create efficient, economical material removal.
Acceleration and deceleration control is essential to control functions in CNC systems. It has a significant impact on the system’s accuracy and performance. In high-speed machining, acceleration and deceleration control is particularly important.
For example, if you needed to rough out a pocket in the center with a depth of 1.2 inches. Standard roughing possibly would take 0.2-inch deep cuts using as much of the cutter diameter as possible. At the end of this first stage, it would leave a level floor-type look. Through OptiRough, the technique looks different. This technique would start with a 0.6-inch depth with up-cuts at each 0.2-inch internal to the surface. This method creates a floor look, but with a stair step shape at height 0.2-inch up-cuts the program would then repeat at another 0.6- inch depth with 0.2-inch up-cuts.
What are some of the benefits of OptiRough?
Tests conducted by the developer indicate that OptiRough technique leaves the same desired roughness as the standard approach. However, it uses far less machining time and lighter, consistent wear on the cutting edges. If lighter and faster machining doesn’t sell you, then there’s more. OptiRough can also save you money. Small carbide tools are likely to be less expensive than the larger counterparts because they use smaller amounts of the costly carbide material. As well, no time is wasted switching between larger and smaller cutters; minimizing the time of roughing routine.
If you are ready to take you roughing to the next level consider Mastercam software for your company. With our experienced staff and monthly events and training, you are sure to be able to take your CNC skills to the next level.
About the author
Kim Dugas has been a Solution Specialist at MLC CAD Systems for the last 13 years, in Louisiana, Mississippi and Arkansas. He provides Mastercam Software and Services to help with Manufacturing and Production for all types of parts.
