August 21, 2013
Dutch tooling manufacturer Van Hoorn Carbide changed their CAM solution to Edgecam, following machining tests using Edgecam’s Waveform Roughing strategy.
Edgecam reseller Widenhorn Industriële Automatisering also used Waveform for machining demonstrations during Van Hoorn Carbide’s four recent technology days. WIA Support Manager Michael van de Velde, says visitors found the results “astonishing,” and many intend to use Van Hoorn’s cutting tools with the Waveform milling strategies.
Two 100 mm x 100 mm x 40 mm test parts – one in Stainless Steel 304 and the other Aluminium 51ST – were machined on a Mikron VCP600 with a Heidenhain iTNC530 controller, using solid carbide end mills.
“The results clearly demonstrated the benefits of Wave milling,” says Michael van de Velde. “The Material Removal Rate for the stainless steel part was 36.6 cm3, in a cycle time of four minutes and 19 seconds, with a feed rate of 573 mm per minute, using a tool diameter of 8 mm, at a speed of 3,581 rpm, stepover of 50%, and a 16 mm cutting depth.
“For the aluminium part, the Material Removal Rate was 716.2 cm3, in a cycle time of just one minute 28 seconds, feed rate of 7,162 mm per minute, with a tool diameter of 10 mm, cutting speed 15,915 rpm, a stepover of 50%, and a cutting depth of 20 mm.”
The four technology days were attended by both Edgecam and Van Hoorn Carbide customers, and the demonstrations were geared towards educating them about the new possibilities that Waveform brings.
Waveform Roughing is a high speed machining technique that maintains a constant tool cutting load by ensuring consistent tool engagement with the material. The toolpath moves smoothly to avoid sharp changes in direction, maintaining the machine tool’s velocity.
Michael van de Velde says WIA has examples where Waveform has slashed cycle times by more than 75% compared to traditional milling techniques. “Also there is much less wear on the tool, the machining process is more reliable, there is constant chip load, and the operator doesn’t need to stay with the machine to adjust feedrates in corners and other tight areas. Waveform increases cutting tool life, utilises the complete length of the flute and reduces cycle times, all of which drives down costs.”
As an added bonus, manufacturers at the technology days also saw WIA use Edgecam for a demonstration of 3D milling.
The partnership between Van Hoorn Carbide and WIA enables Van Hoorn to use Edgecam to test their tools, and WIA use Van Hoorn tools to test Edgecam on their Fehlmann CNC machine. Edgecam’s Strategic Partnership Manager, Wesley Tonks, says: “This collaboration of experts working together provides an optimum process, with manufacturers benefitting from the productivity solutions of using Van Hoorn’s solid carbide end mill cutting tools with waveform roughing. It ensures each discipline is fully utilised, as both partners fully engage with the latest technology available in the market place today.”
Videos of the machining at Widenhorn Industriële Automatisering can be found on Edgecam’s Waveform video wall: http://www.edgecam.com/WIA-videowall
