components New CNC
components New CNC software simplifies usage of latest five-axis machine tools Available now, the latest version of Flexium software from CNC specialist NUM includes an enhanced RTCP (Rotation Tool Center Point) function with tool vector programming that significantly simplifies the usage of five-axis machine tools. As one of the original developers of RTCP, NUM continually enhances the function to meet the changing needs of machine builders and end-users. The company’s implementation of RTCP includes twenty-four predefined kinematic configurations and its Flexium+ CNC systems can accommodate different kinematics on the same machine, for example, when different milling heads are needed. NUM’s basic RTCP function, invoked by ISO code G151, offers a number of user-specified variants. The function can be activated with an inclined coordinate system or after a positioning move. In either case, the CNC system automatically calculates the mechanical offset to ensure that the tool center point is always in touch with the defined workpiece surface The RTCP function in NUM’s Flexium CNC software can now be activated by the actual positions of the rotary axes The tool vector programming option of NUM’s RTCP function enables the direction of the tool to be determined by the vectors’ components along the X-, Y- and Z-axes, rendering the part program independent of the machine kinematics. In some circumstances, aligning the workpiece to be processed on the machine can be a complex procedure. In these cases, to increase productivity, instead of moving the workpiece, NUM’s Flexium+ CNC system can now compensate for positioning deviations (including angles) by applying appropriate correction values. The workpiece remains misaligned, but the CNC system is aware of the deviations and compensates for them automatically. NUM’s Flexium software, version 4.1.00.00 or higher, now features a special HMI (Human-Machine Interface) to allow the corresponding correction values to be entered. The coordinate system resulting from the shifts and rotations is called a Balanced Coordinate System (or BCS) and the compensation function is known as 3DWPC (3D workpiece compensation). NUM’s Flexium CNC software now includes an enhanced RTCP function with 3D workpiece compensation that significantly simplifies the programming of five-axis machine tools Also the software now includes a function to help machine users accelerate the roughing operation’s tunings and then achieve optimal surface finishes. Invoked by ISO code G732, the new function simplifies parameter optimisation and automatically computes pre-settings for roughing and finishing with adjustable smoothing levels. while the rotary axes are moving. The RTCP function can also be activated by the actual positions of the rotary axes. Until now, programming 5-axis machines has often been considered an onerous task. The rotary axes are usually programmed directly with their angular position, which has the advantage that the position of the machining head can be imagined when viewing the part program. The disadvantage is that the part program depends on the kinematics of the machine, and cannot be transferred to another 5-axis machine without modification. To help machine operators achieve optimal results, NUM has introduced a new algorithm that keeps the pivot point at constant speed. Part programs generated by CAD/CAM systems invariably comprise a multitude of small G01 segments – in the case of rotary axes, these are often distributed inhomogeneously – resulting in speed variations which affect surface quality. The new algorithms maintain constant speed at pivot points during the movement of rotary axes, smoothing the discon tinuities, resulting in an improved surface. further information: www.num.com 46 no. 1, March 2022
components New lubricant for mask production The manufacturer of ultrasonic welding equipment for mask production, among other things, wanted more process reliability in the machining of materials that are difficult to machine: with tools from Paul Horn GmbH and cooling lubricants from Zeller+Gmelin, the Karlsbad-based specialist for ultrasonic components and systems was able to find two suitable partners at once. Ultrasonic welding from Weber Ultrasonics is used for the production of medical masks The ultrasonic sys tems are used, for example, in the production of a wide variety of medical technology applications,- for example medical masks or components such as membranes, adapters, connectors and even sur - gical instruments. In particular, the demand for ultrasonic welding technology for the series production of medical masks made of non-woven fabric has increased dramatically due to the pandemic. The ver - tical range of manufacture at Weber Ultrasonics is enormous: almost all components and assemblies of the ultrasonic systems are manufactured in-house. For a special titanium component, the so-called converter, the machining process used is grooving, or more precisely axial grooving. In order to be able to guarantee process reliability and long tool life even with increasing quantities, new tool solutions were sought. Previously, chatter marks on the surface of the deep grooves were a recurring problem. Zubora ensures more process reliability With a new axial grooving system from the Tübingen tool specialist Horn, a process-safe solution was found: the new S15A grooving insert had produced a stable machining process right away. At the same time, a new cooling lubricant is used in the form of Zubora TTS, which was developed in a joint project between Horn, Zeller+Gmelin and a major machine manufacturer. “All the experience of the lubricant manufacturer, machine builder and tool specialist has gone into the development of the new lubricant,” says Jürgen Schmid, product and project manager sales at Horn, seeing By using the newly developed cooling lubricant Zubora TTS in combination with the axial grooving system from Paul Horn, swirl chips are now optimally broken during the machining of pure titanium TiAI6V4 and ensure a safe process an enormous advantage. “The idea of the project was to develop a new and more efficient coolant for the machining of superalloys. Zeller+Gmelin has achieved this with the development of the new coolant.” And business unit manager Thorsten Wechmann from Zeller+Gmelin adds: “After successful tests on various superalloys, the first field test at Weber Ultrasonics was now on the agenda. By using Zubora TTS in combination with a new tool coating, the tool life could be significantly increased. The completely new formulation leads not only to an increase in tool life but also to an improvement in the surface quality of the component. Furthermore, it was possible to increase the cutting parameters and thus sustainably increase profitability.” Chip breaking under control Weber Ultrasonics says that by optimally matching the tool and the cooling lubricant, it has been possible to significantly improve chip control. As a result, 50 of the titanium components can now be produced off the shelf in an unmanned shift, so to speak, and the problem of uncontrolled long chips is now a thing of the past. Tool wear has also improved measurably and visibly thanks to the new Zubora coolant. The new cooling lubricant Zubora TTS is a fully synthetic solution. According to manufacturer Zeller+Gmelin, the focus of the novel concept was on lubrication, chip breakage support and surface quality improvement. “We have developed the new coolant for the productive machining of titanium and other super alloys. However, the product can be used multifunctionally and also brings advantages when machining a variety of other materials,” explains Thorsten Wechmann. further information: www.zeller-gmelin.de no. 1, March 2022 47
