Simulating and optimizing multitasking: 5-Axis Machining

More than ever, it is crucial that North American part manufacturers constantly improve their technology and processes to compete globally. As a result, they are increasingly using multitask machine tools, which are engineered to mill and turn complex features with high accuracy and quality. These applications, however, create the challenge of initially obtaining a safe and optimal NC program to reduce machine downtime and program prove out.

Multitask machines typically consist of multiple spindles and turrets, which can operate independently or in synchronization. All six sides of a part can be roughed and finished in a single setup, allowing production batches to be run lights-out. In addition, parallel operation allows a manufacturer to simultaneously perform multiple operations on the part, saving significant time.

All images courtesy of CAMplete Solutions

CAMplete TruePath TurnMill is an integrated post-processing verification, simulation and optimization platform exclusively for Nakamura-Tome multitask machines. The software’s detailed machine models provide an accurate offline setup verification tool.

In traditional multitasking, programmers and operators must optimize the process to take advantage of a machine’s capabilities. This means long setup times on the machine and extensive part prove outs, both of which can be costly. There is always a trade-off between spending more time on optimization—and therefore increasing machine downtime—and the cycle-time reduction that optimization achieves.

To maximize multitask machine utilization, a user needs an integrated software package that “intelligently” post-processes, simulates and optimizes programs, such as CAMplete TruePath TurnMill. The software was developed in partnership with Methods Machine Tools Inc., Sudbury, Mass., exclusively for Nakamura-Tome multitask machines, which Methods distributes.

TruePath TurnMill helps programmers reduce setup time by using intelligent tools to automatically detect and assign cutting tools to the proper channel and turret and dynamically try and prove multiple setup options to determine the most appropriate one for a particular part.

Programmers use the software to generate NC programs using input from their CAM systems. They can even reuse NC code from other machines. After generating the NC code, the software simulates and optimizes the programs before they are run on the multi- task machine.