New software added to TNC controls

Heidenhain has incorporated new software into its TNC control systems that allows complex trochoidal milling routines to be programmed conversationally on the shop floor, without having to download the cycles from a CADCAM station

OCM (optimised contour milling) functionality is a new option available for the company’s TNC640, TNC 620 and TNC 320 CNC systems.
The OCM algorithm takes conventional ideas for trochoidal milling, traditionally used to achieve high material removal rates when slotting, and considerably expands the range of application. In addition to the roughing of any open or closed pocket or island, the software also offers cycles for finishing the floors and side walls.
A milling tool’s wrap angle can be limited to reduce heat generation and prolong cutter life. As cutting forces are lower, delicate and thin-wall parts can be machined with greater accuracy, and even spindles with low power and torque can be used successfully, says the company. Moreover, as the milling cutter occupies less of the area of a slot or pocket during machining, the accumulation and re-cutting of chips is minimised, which is particularly important for features that are deep in comparison with their width.
The control automatically calculates the best tool paths for maintaining constant cutting parameters. Subsequent machining operations run with continuously optimised cutting values, resulting in increased machining speed and a noticeable reduction in tool wear, reports Heidenhain. A sample part produced recently in Germany demonstrated the effectiveness of the new milling strategy: OCM lowered the machining time and raised tool life by a factor of three compared with conventional milling strategies.
For further information www.heidenhain.co.uk

COVID secure

Companies looking to return back to work safely can tap into a new service launched by In-Comm Training that will help them become COVID-19 secure.

Health and safety experts from the Aldridge-based training provider have created a new consultancy package that will walk firms through the different measures and policies they need to put in place to protect their staff and conform to Government guidelines. The support will also help businesses with more than 50 employees, who must have a COVID risk assessment available for staff and visitors before they can open.
For further information www.in-comm.co.uk

Major release from ModuleWorks

ModuleWorks has released its 2020.04 CADCAM software components – the first major release of 2020 – which is available now for download from the ModuleWorks website.

Each ModuleWorks release contains new and enhanced features across the product range. This latest release contains new quality-enhancing features for five-axis and three-axis machining, as well as improved visualisation for the MultiXPost post processor.
In five-axis machining it is not always possible to create a collision-free lead for the machining process. The new automatic tilting feature uses an intelligent algorithm to automatically tilt the tool to avoid collisions, thereby improving the safety and efficiency of the machining process, particularly when working with complex tool shapes such as barrel-mill cutters.
Setting the constraints on the lead tilt angle and side tilt angle enables users to adjust the machining process in different ways depending on the tool’s contact point and the machining surface. To provide even more application flexibility, the user-defined contact point and angle limits can now be measured relative to the surface normal, instead of the initial tool orientation. When working with barrel-mill cutters, this feature gives users better control over the cutting conditions upon tool engagement.
With regard to three-axis operations, floor machining for pocket/boss areas is now available to complete the basic product portfolio of roughing and finishing cycles based on a wire-frame geometry. This new cycle creates engrave cuts at a specified depth. The pattern can be used with open and intersecting drive curves and is suitable for engraving text and single-line font machining. To optimise tool loading, users can now create a specified number of engraving tool-path slices with variable depths.
The posting of three-axis tool paths on a machine usually requires constant adjustments to the position of the table or head, which may not always be desired when viewing the simulation. To provide an improved user experience, MultiXPost is now able to eliminate continuous movement and keep the table or head axis in a fixed position while ensuring the whole tool path is simulated within the machine limits.
For further information www.moduleworks.com

Open Mind helps fast-track COVID-19 project

Letchworth-based Maztech Precision Engineering (MPE), a prominent supplier to the F1 sector, is finding that – with F1 teams so heavily involved in the COVID-19 ventilator project – that is now making component for ventilators.

Indeed, Maztech has won an order to produce 7500 aluminium tube manifold components. The company is now running its four Mazak machining centres 24 hours a day, seven days a week, including a recently installed VariAxis i-300 AWC five-axis model.
“I had a CAM system, but it couldn’t provide suitable post-processors to communicate confidently with the VariAxis configuration,” says managing director Wayne Bouchier. “I also wanted full machine capability, so I could simulate everything, as the machine is a big investment.
“I called Open Mind and had Ken Baldwin come and give me a demonstration,” he adds. “Entering five-axis machining is never easy, but hyperMILL simplified things and made it no more complicated than necessary. After the demonstration, I was very confident in the system and didn’t need to look at any other CAM systems, so we bought our first seat of hyperMILL.”
The company now has three seats of hyperMILL: two seats with a 3+2 axis licence and the third with a full simultaneous five-axis licence. Following advice from numerous motorsport subcontractors, Maztech specified the hyperMILL Maxx Machining package for high-performance metal removal rates.
“Our programming times are at least 35-40% faster with hyperMILL,” adds Bouchier. “One example of this is the mirror function within the software. More than 30% of our work has a left and right-hand variant; hyperMILL and its mirror function is slashing programming times from hours to minutes for these parts.”
For further information www.openmind-tech.com

Rolls-Royce installs ultrasonic washer

Guyson International has delivered and installed a further precision cleaning machine to Rolls-Royce in Bristol for the Ventilator Challenge UK consortium.

This latest Guyson ‘Kerry’ branded Microsolve 250, which was built in record time, has three process stages comprising ultrasonic cleaning, vapour rinsing and freeboard drying. This configuration provides precision cleaning of components used in the ventilators and, crucially, is already cleared by regulators as it is being used by an existing manufacturing company.
For further information www.guyson.co.uk