2002017 EBSCOnost
Registro: 4
Titulo: CAD/CAM Considerations For Micromilling
Autores: Korn, Derek
Fonte: Modern Machine Shop. Feb2006, Vol. 78 Issue 9, p84-87. 4p. 1 Color
Photograph, 1 Diagram.
Tipo de documento: Article
Termos do assunto: Milling (Metalwork)
Manufacturing processes
Machine-tools
Metalwork
Metal cutting
Resumo: The article discusses the factors to be considered when generating
tool paths for micromilling applications. According to Cimatron product
manager Uri Shakked, itis important to develop machining strategies
that are appropriate for micromilling. Uri Shakked also stated that
equipment manufacturers should prefer conventional milling than
climb milling
Contagem de palavras do texto 1516
completo: 9926-8003
ISSN: 19858231
Numero de acesso: Computers & Applied Sciences Complete
Base de dados: CADICAM Considerations For Micromilling
Milling with tools that are smaller than 100 microns in diameter presents equipment design and toolpath-
generation challenges. This NC software maker offers strategies for creating safe, optimized tool paths for
micromiling
The challenges involved in designing machine tools, cutting tools and fixtures to effectively mill features on
miniature molds and microcomponents are daunting. The same could be said for optimizing tool paths for a
tool that a machine operator probably won't be able to see or hear while i’s in cut. Unlike standard milling
operations, there's no way that a machine operator can tell just how a tool is behaving while cutting in order to
make the necessary changes to optimize the process. In addition, the toolpath strategies that might be
suitable for "typical" milling work do not always scale down elegantly to work for micromilling applications.
Still, there is an increasing demand for small part machining of medical, electronics and optic components
Recognizing this trend, the Fraunhofer Institute for Production Technology (IPT) in Aachen, Germany,
recently sponsored a micromilling research project that brought together machine tool equipment
manufacturers and mold makers with the goal of developing effective micro-moldmaking strategies and
processes. The struggle in creating NC software for micromilling has been effectively calculating tool motions
a tolerance of 0.1 micron. Cimatron (Novi, Michigan) is one software company that took part in the IPT
project. The result was upgrading Cimatron & NC software to include a variety of functions for micromiling
work.
Uri Shakked, a product manager for Cimatron who specializes in micromiling, offers the following five
considerations when generating tool paths for micromilling applications.
1) Develop machining strategies appropriate for micromilling. Similarities between high speed
machining (HSM) and micromilling do exist, such as avoiding sharp tool motions. When approaching corners,
tool paths should be rounded, and the amount of that roundness depends on the machine tool and the feed
rate. When micromilling, rounding becomes virtually useless below a certain value, Rounding of 0.2 mm, for
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‘example, is too large because typical micromilling stepovers are extremely small (approximately 0.01 mm). In
this example, the roundness value is 20 times that of the stepover value, which means there would be wide
gaps between sequential passes, high scallop height and poor surface quality
The zero-overlap trochoidal method developed by Cimatron offers a way to clean such ridges. This method
machines all relevant areas in a trochoidal style, but in order to prevent double-machining, tool back motions
are raised from the workpiece surface in the Z axis. The tool then plunges tangent to the tool path on
‘succeeding forward motions (see image on the following page).
HSM uses high cutting feeds to allow the chip to remove the heat that results from cutting; high spindle
‘speeds to generate high cutting feeds; and high feed rates to reduce machining time and allow cutting with
‘small stepover values. The feed rate, though, is limited by the tool's maximum chip size per cutting edge.
Because micromiling cutting tools have such small diameters, the spindle speed is often too slow to produce
a high cutting feed, which, in tur, limits the maximum attainable feed rate. For example, to maintain a cutting
feed of 100 meters per minute with a 10-mm cutter, the spindle should rotate at approximately 3,200 rpm. For
a0.1-mm cutter, the spindle would have to rotate at 320,000 rpm, Such a high spindle speed currently isn’t
available. The maximum cutting feed possible with a 0.1 mm cutter is approximately 15 meters per minute~far
from being considered HSM.
2) Conventional milling is generally more effective than climb milling. The decision whether to use
‘conventional or climb milling for micromilling applications depends largely on the part feature being machined.
Considering the delicate features typically found on micromolds and microcomponents, conventional milling is
generally the milling method of choice
Conventional milling is best suited for micromilling when the tool is long or the workpiece wall is very thin. As
cutting edge starts a conventional milling cut, the chip size is essentially zero and becomes thicker as the
tool rotates. As the cutting edge penetrates the material, the force between them builds and the cutting edge
tends to be drawn into the workpiece. This provides for a stable cutting condition that is well-suited for soft
materials and delicate features.
However, conventional milling can potentially damage the tool's cutting edge. As the cutting edge finishes the
ccut, it pushes away from the material. As it rotates back into a cut, it digs into the material. This causes the
force on the cutting edge to rapidly change directions, shortening tool life.
In climb milling, the cutter engages the material at maximum chip size, and the tool and the part tend to push
away from each other. The machine tool, workpiece and cutting tool must be robust enough so that vibrations
are not introduced, Otherwise, cutting tool life would be shortened and surface quality would be poor.
3) Combined roughing/finishing operations may be necessary. Roughing and finishing passes are
traditionally performed as separate operations, using different spindle speeds, feed rates and depth of cut.
However, this might not be possible when micromilling, especially when machining tall, thin walls or bosses
‘on miniature parts, The wall thickness after a roughing operation will not provide sufficient support for the
finishing operation, causing the walls to vibrate or possibly fracture during finish milling. At the very least, wall
surface finish would be unacceptable.
When micromilling, cutting thin walls, roughing and finishing should be combined into a single operation,
cutting layer-by-layer down the Z axis on alternating sides of the wall. The cutter should be tilted away from
the wall to guarantee a single contact point between the cutter and the wall
4) Constant tool load should be maintained. In standard moldmaking applications, a machine operator will
often manually adjust feed rates, change tools if needed or manually edit the tool path to make it more
efficient. Because of the miniature size of the part and tools used in micromilling, an operator has no practical
way to see or hear what's going on during the machining process. That's why the micromilling software must
be able to accurately maintain a constant chip load throughout the cut.
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Cimatron software recognizes actual remaining stock and uses that knowledge to make adjustments
depending on the tool load throughout the entire process, This quickens machining time while protecting the
delicate micromilling tools from breaking. During a roughing operation, in which the workpiece shape is
changed dramatically, the software simulates the remaining stock after each layer. This enables the tool to go
into locations that were cleaned by previous layers, thus allowing short tools to cut into deep areas.
During a clean-up operation, the system can detect excessive material and automatically apply re-roughing
operations. The re-roughing motions prevent tool breakage, maintain constant tool load and deliver higher
surface quality. Depending on how much material is removed, the software will automatically make changes
to the feed rate or possibly divide the tool path into several down passes.
5) Be mindful of CAD/CAM translation problems. Data translation errors between separate CAD and
CAM packages adversely affect machining accuracy, and these inaccuracies are exacerbated when
icromiling, Integrated CAD/CAM pack ages eliminate such data translations. For example, a translation
error resulting in a 0.005-mm gap between two surfaces on a relatively large part might not be problematic
because the part could be polished. Polishing often isn't possible on miniature molds or microcomponents, so
a gap of the same size on a micromilled part would clearly be visible.
‘Almost any CAM programming job requires some geometry-mending procedures, which means CAM
software should include built-in CAD capabilities. When making a mold, cooling and ejector holes are typically
‘capped to prevent the cutting tool from machining into them. Also, surfaces must be extended to protect areas
that will be machined in another setup and a draft angle will be applied. The ability, or inability, to create or
modify part geometry impacts the way the tool path is programmed.
This CAD-for-tooling work should be done by a toolmaker who knows the needs of the machining process,
such as the NC programmer. In many cases, only during the programming process does it become clear that
a certain geometry modification is required.
LEARN MORE
www.mmsontine.com
* The Changing Face Of CNC Programming
Efforts to create a CNC-usable product data model are inching forward, but in the meantime, advances in
CAM software will make the programmer's job function more efficient.
Find a link to this at www.mmsonline.com/ articles/020603,htm.
MMS Direct
For more information from Cimatron, call (248) 596-9700 or enter MMS Direct code 275ZP at
www.mmsonline.com
PHOTO (COLOR): Milling with cutting tools that measure 0.1 mm in diameter, such as the one shown here,
creates challenges for both equipment and programming software.
DIAGRAM: Ridges that remain when milling a tight radius can be cleaned using a zero-overlap trochoidal tool
path. In this method, tool back motions are raised from the workpiece in the Z axis and the tool then plunges
tangent to the tool path on succeeding forward motions to create a better surface finish
By Derek Korn
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