Delcam software enables lights-out prototypes for Noddy car

Omega Plastics, part of the Fitstogether Group based in the North-east UK, used Delcam software to produce parts for prototypes of a Noddy pedal car for Premier Pedal Cars Ltd. (PPC).

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IMTS
12/9/2016-17/09/2016
Chicago IL, USA
Stand: E-3222
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BI-MU
4/10/2016-08/10/2016
Milan, Italy
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EMO Hanover
18/9/2017-23/09/2017
Hannover, Germany
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• Controlled Engagement Angle

• Increased Tool Life

• Efficient Roughing On Any Part

• Seamless Integration

• Step Cutting

• Automatic Flat Area Detection

• Controlled Engagement Angle Vortex is Delcam’s latest patent pending high speed roughing technology. Vortex controls the maximum engagement angle of the cutter in the material, such that the angle calculated for the programmed step over is never exceeded, even in internal corners. This allows for optimal cutting conditions to be maintained throughout the toolpath. By controlling the maximum engagement angle and the load on the tool, Vortex can take deeper cuts than traditionally used in roughing operations. Depths of cut up to the full flute length enable maximum material removal rate from solid carbide tooling and reduce machining times by up to 60%. Vortex technology can be applied to 2 and 3-axis roughing, positional 5-axis roughing and for rest roughing. In comparison, when conventional roughing the feed rate is often reduced in internal corners to compensate for the increased engagement angle which in turn increases the forces on the tool. Reducing the feed rate leads to longer machining times.

• Increased Tool Life Vortex significantly increases tool life and reduce tooling costs. Customer tests have proven that in many cases a single Vortex roughing strategy can replace several conventional strategies, thus reducing the number of tools required for roughing. Cutting trials have demonstrated that Vortex greatly extends tool life. Consistent cutting forces on the tool help to reduce tool wear. In addition this tool wear is spread evenly across the full flute length. The controlled engagement angle also ensures the tool is never suddenly overloaded, eliminating any chance of premature tool failure or chipping of the cutting edge. In addition, stable cutting conditions give a more constant edge temperature, prolonging the life of the tool coating and protecting against heat damage to the surface of the part. The benefits to tool life from Vortex can even be heard on the machine. Vortex produces a constant pitch while machining, indicating that the tool is operating under consistent load and cutting conditions. In comparison, conventional roughing will often produce sounds of varying pitch indicating constantly changing load on the tool (e.g. tool chatter in corners). Not only will you be able to hear the difference, you’ll be able to see the difference. Vortex produces chips with a regular size and thickness, providing further evidence of the consistency of the cut.

• Efficient Roughing On Any Part Unlike alternative high speed roughing methods, Vortex is based on generating offsets from the part profile. This produces an efficient toolpath regardless of the part shape. This eliminates the need for any unnecessary techniques for moating or bridging. These offsets are then grouped and ordered efficiently to reduce the number of trochoids required while still controlling the engagement angle. This is particularly beneficial for rest roughing with smaller tools when there is only a small amount of material to be removed. In addition, Vortex automatically removes any toolpath segments when a slot or channel is too narrow to be efficiently and safely machined using the trochoidal method.

• Seamless Integration Vortex and MachineDNA are integrated across Delcam’s entire CAM software product range. Applying a Vortex roughing strategy is as easy as using any other roughing strategy. Vortex toolpaths can be enhanced even further with the integration of MachineDNA, which optimises the strategy for your specific machine tools (for more info click HERE).

• Step Cutting Delcam’s step-cutting functionality can be combined with Vortex to produce a single toolpath that quickly and efficiently roughs the part without leaving any large terraces that would typically require a separate operation. After machining an initial step down up to full flute length, the tool will step back up the part to remove the rest material before commencing with the next step down. During the step-up cutting material removal rates can be maintained by automatically increasing the feed rate as the depth of cut decreases.

• Automatic Flat Area Detection Vortex can be combined with Delcam’s automatic flat area detection technology, ensuring that the roughing strategy never leaves any excess material on flat planes.