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IndustryArena Forum > GENERAL MANUFACTURING PROCESSES > MILLING > VoluMill Evaluation in ZW3D 2019-2
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  1. #1
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    Dec 2018
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    Lightbulb VoluMill Evaluation in ZW3D 2019-2

    Why VoluMill Can Extend Cutting Tool Life?

    What is the difference between VoluMill (a high-speed machining technology) and traditional roughing? We have made some comparisons between traditional machining and VoluMill machining, and found that their tool paths are completely different.

    First, take traditional processing which uses Offset 2D operation as an example.

    The traditional machining tool paths are at the corner of the machining, and when machining a small area as shown in the figure below. The tool paths of the step will be extended, and the tool load will be increased accordingly, then tool loss may occur.

    On the contrary, allthe VoluMill tool paths maintain constant path and cutting step. The toolpath always drives the tool along a high-speed continuous tangent motion, as well as under a constant stepover and cutting load, thus resulting in uniform chip formation, excellent heat evacuation and a much faster speed/Feed.

    What’s more, VoluMill always tries to use the entire flute length of tools, which not only reduce wear, but also increase milling speed to the highest level. At the same time, it can maintain a stable material removal rate and automatically adjust the cutting step distance, which effectively protect the machine tool and extend the tool life.

    Through the above analysis and comparison of the tool path, we have done a comparison test between traditional roughing and VoluMill machining, indicating VoluMill can dramatically extend tool life, up to 800%.

    Performance
    Here are the details of one of the tests.

    Material: 16MnCr5
    Part Size: 178X145X50mm
    Machine: DMU 60
    Controller: Heidenhain
    Date: 2018-09-27
    Tool: D10R0

    Traditional Operations
    Machining Time:137.29min
    Speed: 6000RPM
    Feed Rate: 3000MMPM
    Step-down: 0.4mm

    VoluMill
    Machining Time:33.68min
    Speed: 6000RPM
    Feed Rate: 3000MMPM
    Step-down: 12mm

    From the above table, the huge gap in processing time can reflect from the side why VoluMill processing can significantly extend tool life. For example, traditional roughing may require three cutters to complete roughing of multiple parts, but with VoluMill roughing, it may only require one cutter to complete roughing of multiple parts, which saves tool costs.

    Conclusion

    As one of the fastest toolpath engines throughout the world, VoluMill saves your machining costs based on its amazing powerful algorithm. It is proved to work perfectly in ZW3D.

    Have you tried VoluMill? What do you think about VoluMill for ZW3D? Welcome to leave your comment here.

    If you want to try it, click: www.zwsoft.com/zw3d/download-center
    Learn more about ZW3D 2019: www.zwsoft.com/zw3d/overview
    More details of the tests: https://www.zwsoft.com/forum/thread-14990-1-1.html

    Written by Anson Liu, Senior CAM Engineer
    Anson Liu is experienced in ZW3D products, especially in CAM processing. Involving in the new CAM projects of ZW3D, he is good at research and willing to share technical knowledge.

  2. #2
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    Join Date
    Jan 2019
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    74
    How does Volumill handle sharp corners and islands? I am currently using mastercam dynamic milling. The problems I am having with sharp corners is MC will cut out the stock, depending on the shape, it will sometimes leave a sharp angle "V" that it cuts. Additional passes thrying the remove this "V" sometimes causes the endmill to break as the thin material gets caught in the flutes.
    The same happens when it starts cutting down small width islands. The islands break off and destroy the endmill.

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