High-alloy steels, titanium alloys and carbon fiber-reinforced plastics are difficult-to-machine materials at the center of numerous key technologies. Only specially designed, high-performance tools, however, have a chance of achieving economic results when cutting these materials.
With Rollomatic’s VirtualGrind Pro grinding software, tool developers can program even complex tools. The software is tailored to Rollomatic GrindSmart tool grinding machines. A uniform user interface makes it compatible for tool developers, production managers and machine operators.
Courtesy of Rollomatic
Rollomatic’s VirtualGrind Pro grinding software provides 3-D simulation of grinding movements, including virtual collision detection.
The development of VirtualGrind Pro is based on more than 20 years of experience in tool grinding and customer requirements for tool production. Since debuting the software at the GrindTec 2010 event in Augsburg, Germany, Rollomatic has released Version 1.05 with its new machines and offers it as an update for existing systems.
The new version has new features and extensions for programming the GrindSmart machines, providing more performance and creative freedom in tool design. A highlight is the new programming assistant, called the “Tool Wizard.” It guides users through a database of standard industrial tools that can be modified. Developers can create a complex and unique tool with a few mouse clicks. They select a basic tool suitable for the relevant application and typically alter the helix, cutting or relief angle, while defining feeds, core diameters and other variables. Users can select a constant- or variable-helix angle or a combination of both per tooth, for example, to provide a smooth cutting action and therefore extend tool life through chatter-reducing asymmetry.
Users can also select the grinding wheels and parameters suitable for the specific application with the software. In addition, a 3-D simulation of grinding movements is available for all tool types. That includes virtual collision detection to optimize setup times. Simulation lets users see whether a tool can be produced with the grinding wheel combination selected without any problems.
If corresponding DXF files from a CAD application already exist for complex tool geometries, the files can be imported into VirtualGrind Pro or entered via the integrated 2-D editor. Users can also modify or correct the tool profile. They do not have to be CAD experts to do this, because the editor is simple to operate. Therefore, helical flutes and axial shear angles can be efficiently programmed. It is also possible to compile the results via the export function as a JPEG or 3-D image format so toolmakers’ customers can view them.
Despite a self-explanatory installation routine and ease of use, the software’s full potential can only be realized after training. Users can be shown the required steps in detail as part of introductory and advanced training. Free updates allow users to keep pace with new software developments.
After using VirtualGrind Pro, users can communicate cutting tool designs directly to the grinding machine. CTE
About the Author: Jean-Charles Marty is product manager for Rollomatic SA, Le Landeron, Switzerland. For more information about the company’s grinding machines and software, call (866) 713-6398, visit www.rollomaticusa.com or enter #350 on the I.S. Form on page 3.
Related Glossary Terms
- 2-D
2-D
Way of displaying real-world objects on a flat surface, showing only height and width. This system uses only the X and Y axes.
- 3-D
3-D
Way of displaying real-world objects in a natural way by showing depth, height and width. This system uses the X, Y and Z axes.
- alloys
alloys
Substances having metallic properties and being composed of two or more chemical elements of which at least one is a metal.
- computer-aided design ( CAD)
computer-aided design ( CAD)
Product-design functions performed with the help of computers and special software.
- flutes
flutes
Grooves and spaces in the body of a tool that permit chip removal from, and cutting-fluid application to, the point of cut.
- grinding
grinding
Machining operation in which material is removed from the workpiece by a powered abrasive wheel, stone, belt, paste, sheet, compound, slurry, etc. Takes various forms: surface grinding (creates flat and/or squared surfaces); cylindrical grinding (for external cylindrical and tapered shapes, fillets, undercuts, etc.); centerless grinding; chamfering; thread and form grinding; tool and cutter grinding; offhand grinding; lapping and polishing (grinding with extremely fine grits to create ultrasmooth surfaces); honing; and disc grinding.
- grinding machine
grinding machine
Powers a grinding wheel or other abrasive tool for the purpose of removing metal and finishing workpieces to close tolerances. Provides smooth, square, parallel and accurate workpiece surfaces. When ultrasmooth surfaces and finishes on the order of microns are required, lapping and honing machines (precision grinders that run abrasives with extremely fine, uniform grits) are used. In its “finishing” role, the grinder is perhaps the most widely used machine tool. Various styles are available: bench and pedestal grinders for sharpening lathe bits and drills; surface grinders for producing square, parallel, smooth and accurate parts; cylindrical and centerless grinders; center-hole grinders; form grinders; facemill and endmill grinders; gear-cutting grinders; jig grinders; abrasive belt (backstand, swing-frame, belt-roll) grinders; tool and cutter grinders for sharpening and resharpening cutting tools; carbide grinders; hand-held die grinders; and abrasive cutoff saws.
- grinding wheel
grinding wheel
Wheel formed from abrasive material mixed in a suitable matrix. Takes a variety of shapes but falls into two basic categories: one that cuts on its periphery, as in reciprocating grinding, and one that cuts on its side or face, as in tool and cutter grinding.
- relief
relief
Space provided behind the cutting edges to prevent rubbing. Sometimes called primary relief. Secondary relief provides additional space behind primary relief. Relief on end teeth is axial relief; relief on side teeth is peripheral relief.
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