Software
although we would probably need a machine with different kinematics as the test part was quite small.” The Mercedes-AMG PETRONAS Formula One Team confirms that the 25% cycle- time saving for the test part would translate financially, effectively reducing the cost for spindle time by the same percentage. With costs for labour, raw materials and energy currently very high, reducing component cycle times is today more important than ever. The potential “The ability to machine 10 parts in a day instead of eight, for example, would be huge for us,” states Mr Brown. “Moreover, if we scale-up the savings achieved on the trial part to some of our large components with long cycle times, the savings would escalate dramatically. One of our longest-running parts requires 125 hours. Based on the trial, we could likely save around 30-40 hours on this component by using Force. That’s a lot of extra capacity and cost savings.” Force calculates optimal feed rates by analysing factors that include tool geometry and parameters, material characteristics and cutting material, detailed cutting edge geometry and VERICUT Smart Part Technology. The software
calculates cutting conditions using specific material characteristics, taking into account the strength of the material and the effects of friction and temperature. However, Force is about far more than cycle time savings alone. Cut-by-cut analysis of the interaction between the tool edge and workpiece material means the software is adept at predicting tool wear, delivering significant tool life gains in many applications. “Although the trial part was aluminium, we machine around 25-30% of our components from titanium,” says Mr Peddle. “Using Force on these parts would likely extend tool life and generate savings.” VERICUT Force offers a number of key tools that help visualise and identify areas with the biggest opportunity for savings in both cycle time and tool wear. Force graphs, for example, help users see cutting conditions, excessive forces, machining rates, power/torque, chip strength, material removal, tool deflections, and feeds for the original and optimised programs. Mr Brown has the final word: “Although the use of VERICUT Force is just a trial at present, it’s in our mind. We see it as a highly effective production engineering tool.” n
cgtech.com
Machinery & Manufacturing 24
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