Extend tool life with dynamic toolpaths

There are three requirements for achieving long tool life: the cutting tool must be applied correctly, it must be as rigid as possible in its holder, and the CAM programming software must effectively control the tool’s path, speed and entry/exit strategy. The tool’s trajectory is a key element in maximizing its performance. In addition to extending tool life, new CAM software developments enhance machining speed and efficiency.

Courtesy of CNC Software

An OptiRough toolpath can cut material in two directions: step-down (-Z) and step-up (+Z). Large, aggressive down-cuts are followed by fast, smaller up-cuts. This efficient cutting strategy removes the maximum amount of material with the minimum number of step-downs, significantly reducing cycle times.

Courtesy of Iscar Metals

An Iscar CUTGRIP tool cuts with all three sides of the insert: the floor and the walls on both sides. This enables the cutting tool to combine roughing and finishing.

Machine tools have traditionally been driven with algorithms developed years ago, such as a parallel-type machining motion or, perhaps, a collapse/expansion method of calculating the toolpath. While those traditional methods are clearly outmoded, some shops still use them because they understand and trust them. These shops don’t tend to experiment with newer types of motion, such as dynamic toolpaths. As a result, they are missing out on an opportunity to improve productivity.

For example, Mastercam software provides OptiRough, a new technique for quickly removing large amounts of material using a dynamic milling motion. Dynamic milling constantly adjusts the toolpath to ensure the most efficient cut possible and allows the use of the entire tool-flute length, often minimizing the amount of multiple-depth cuts.

Instead, large, aggressive down-cuts are followed by fast, smaller up-cuts because the OptiRough toolpath recognizes the steps created from the previous down-cut and then removes the steps to more efficiently expose the part’s near-net shape.

Traditional methods require more tool travel because the user must program each step-down as a full width instead of simply removing the steps. Optirough optimizes cutter motion because it recognizes the remaining stock and removes material in two directions: step-down (-Z-axis) and step-up (+Z-axis). This bidirectional cutting strategy removes the maximum amount of material with the minimum number of full stock-width steps to achieve the same results, significantly reducing cycle times.