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VoluMill Evaluation in ZW3D 2019 - Why VoluMill Can Extend Cutting Tool Life?

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VoluMill Evaluation in ZW3D 2019 - Why VoluMill Can Extend Cutting Tool Life?

ZWSchool 2019-02-28 08:58:46
What is the difference between VoluMill (a high-speed machining technology) and traditional roughing? We have made some comparisons between traditional machining and VoluMill machining and found that their tool paths are completely different. First, take traditional processing which uses Offset 2D operation as an example. The traditional machining tool paths are at the corner of the machining, and when machining a small area as shown in the figure below. The tool paths of the step will be extended, and the tool load will be increased accordingly, then tool loss may occur.

(Offset 2D toolpath)

On the contrary, all the VoluMill tool paths maintain constant path and cutting step. The toolpath always drives the tool along a high-speed continuous tangent motion, as well as under a constant stepover and cutting load, thus resulting in uniform chip formation, excellent heat evacuation and a much faster speed/Feed.

(Volumill toolpath)

What’s more, VoluMill always tries to use the entire flute length of tools, which not only reduce wearing but also increase milling speed to the highest level. At the same time, it can maintain a stable material removal rate and automatically adjust the cutting step distance, which effectively protects the machine tool and extend the tool life.

(Flute Length)

Through the above analysis and comparison of the tool path, we have done a comparison test between traditional roughing and VoluMill machining, indicating VoluMill can dramatically extend tool life, up to 800%

Performance

Here are the details of one of the tests.

Material: 16MnCr5

Part Size: 178X145X50mm

Machine: DMU 60

Controller: Heidenhain

Date: 2018-09-27

Tool: D10R0

  Traditional Operations VoluMill
Machining Time 137.29 Min. 33.68 Min.
Speed 6000 RPM 6000 RPM
Feed 3000 MMPM 3000 MMPM
Step Down 0.4 mm 12 mm
Toolpath Pattern
From the above table, the huge gap in processing time can reflect from the side why VoluMill processing can significantly extend tool life. For example, traditional roughing may require three cutters to complete roughing of multiple parts, but with VoluMill roughing, it may only require one cutter to complete roughing of multiple parts, which saves tool costs.

(Trial Cut in preparation)

Conclusion

As one of the fastest toolpath engines throughout the world, VoluMill saves your machining costs based on its amazing powerful algorithm. It is proved to work perfectly in ZW3D. Have you tried VoluMill? What do you think about VoluMill for ZW3D?  Welcome to leave your comment here. If you want to try it, click here: www.zwsoft.com/zw3d/download-center Learn more about ZW3D 2019: www.zwsoft.com/zw3d/overview  

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