CG Tech has unveiled a bespoke software package that is said to replicate cutting conditions achieved in real-world applications.
According to CG Tech, its new bespoke software package can replicate the cutting conditions that would be achieved in real-world applications. The software, developed to support the extended use of the company's physics-based Vericut Force optimisation module, was unveiled at the University of Sheffield’s Advanced Manufacturing Research Centre (AMRC).
Force Calibration is a software program to enable material calibration that is applied with the Force CNC Program Optimisation (Milling or Turning) via a material characterisation file. Depending on the material of the cutter and material being cut the encrypted Force material characterisation files adopted by Vericut Force Optimisation are applied to any simulation run to achieve the most efficient NC machining program.
Data for Force material files is compiled from a series of test cuts on a CNC mill and/or lathe with a dynamometer set-up, using a specific cutting tool and the specific workpiece material that is to be characterised. The material (to be cut) and geometry details of the cutter are entered into the software, followed by milling and turning cutting trials being conducted in the machine shop at AMRC. Advanced eight-channel Kistler Dynamometers fitted to the machine tools measured actual cutting forces being generated throughout the trials.
There are five steps required to capture the data required, Vericut Product Specialist Pete Haas said. He explained that step one entails administration and planning, where the raw material and cutting tool are procured along with the determination of location and actual machine tool to be used. Step two includes the experiment design, NC program creation along with set-up instructions. Step three is where Force Calibration comes in with the set-up of the machine tool and dynamometer, preparation of stock material, running of the cutting test with captured data converted for use in the software. Then, with the data loaded into Force Calibration, calibration of the material and validation results follow as steps four and five respectively.
Managing Director Tony Shrewsbury added: “Calibration is not for every business. Many things can go wrong. Experience, training and problem resolution skills are needed. Many engineering companies do not have access to all the hardware required to run a calibration test so we offer this as a very cost-effective technical service.”
He commented that materials only need to be calibrated once and an ISO standard range of over 100 materials have already been compiled in the CG Tech materials catalogue, which are available to customers on. The company is also adding to this list each time it runs a new material calibration test.
The Force module determines the maximum reliable feed rate for a given cutting condition based on four factors: force on the cutter, spindle power, maximum chip thickness and maximum allowable feed rate. It calculates ideal feed rates by analysing tool geometry and performance parameters, material properties of the stock and cutting tool, detailed cutting tool edge geometry as well as cut-by-cut contact conditions by Vericut.
Haas also said that the most powerful and important feature of Force is its understanding of 3D material removal interaction between arbitrary shaped cutters and workpieces for arbitrary motion in space. The improved cutting and time savings are substantial with Force Optimisation.
Shrewsbury added: “Any advanced manufacturing business, within the aerospace or medical sectors for example, should consider Force Calibration for any unique or proprietary materials used. It would ensure the material is machined as efficiently as possible and that the details of its characteristics remain in-house.”