motion, specialized contour ramping and adaptive feed rates to achieve the highest feeds and speeds possible. By leveling tool load, maintaining constant machine-tool motion and using high-speed repositioning, the software produces more effi cient toolpaths, extends tool life and reduces cycle times signifi cantly. A fuel injection manifold that Switzer Dynamics makes
for Reher-Morrison Racing Engines (Arlington, TX) that was previously made with sheet metal fabrication illustrates the capability of VoluMill. The deepest cut they make for three- axis manifold machining is 1" (25.4 mm), although most of the pockets on valleys and fl anges are 1/2" deep. Instead of programming conventionally with two to four passes of 1/4 to 1/8" (6.3–3.1-mm), Switzer programs a single pass at full depth and full speed for everything, relying on VoluMill to generate a smooth toolpath. Although VoluMill has tables of suggested parameters, feeds and speeds, Switzer does everything based on chip load, running at maximum spindle speed and maximum feed
rate. “I enter the tool diameter, the number of fl utes, and my desired chip load per tooth, and VoluMill does the rest,” said Switzer. “It’s easy, and it’s really fast.”
Switzer said that a programmer or machinist who is new to GibbsCAM VoluMill may not understand some of the vari- ables, so he encourages experimentation. “It doesn’t take long to fi gure out what tools can do, what ramp rates work best for a tool’s geometry. VoluMill doesn’t need to know everything. You just tell it a few things, and it does the rest. You don’t have to worry about it squeaking a tool in a corner, or doing something bad. It’s going to be perfect.”
The shop used to make intake runners by hand-rolling sheetmetal or by using radiused dies in a press brake, then welding the seam to close them. They would then build the whole manifold, mount it on a manual mill, and plunge mill the holes in the runners to weld the bungs into them. Now, using the fi ve-axis mill, they make the entire run- ner from aluminum billet, with bungs already on it, ready
DID YOU KNOW…
“PRECISION BY DESIGN” IS THE FOUNDATION OF ALL SPERONI TOOL PRESETTING & MEASURING SYSTEMS
WHAT THIS MEANS FOR YOU:
+ Modularity: The modular design allows for a variety of configurations—offering customized solutions in standard products, and guaranteeing compatibility with future upgrades
+ Repeatability: The pearlitic cast iron design provides thermal stability—guaranteeing precision and repeatability, and eliminating the need for frequent recalibration
+ Longevity: Over fifty years of experience manufacturing future-proof technology through product evolution—so you can be sure your machine will never be obsolete
+ Unparalleled Accuracy: Critical components not manufactured by Speroni are carefully selected—Heidenhain® +/- .00008” precision
scales, Schneeberger® HIGHER PERFORMANCE. GUARANTEED.
Stay in the know at
bigkaiser.com/presetting. Attend our complimentary “Breakfast & Learn” each morning before DMG MORI Chicago Innovation Days. Learn more and sign up at
bigkaiser.com/rsvp.
kaiser1651-04 April Ad
Production_Presetter_SME.indd 1 See us at MFG4 Booth #1026 3/14/14 11:50 AM April 2014 |
ManufacturingEngineeringMedia.com 47 guideways, etc.—in order to guarantee
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