Frequently Asked Questions
What are the benefits to manufacturers?
Manufacturers are constantly challenged with intense competition and are continuously in search of new means with which to produce quality parts within shorter periods of time, and at reduced cost.
The benefits of the ProfitMilling® cycle are a reduction in machine-tool cycle times, increased tool life, decreased programing time, reduced energy consumption and significant productivity improvements - even with light and medium-duty machine tools. Test results have shown that ProfitMilling® typically reduces cycle time by 75% compared to a traditional concentric roughing strategy.
How Does ProfitMilling® work?
ProfitMilling® is a high-speed roughing cycle that allows you to take a significantly deeper cut of the tool and increase the cutting feed. Rather than controlling just one parameter, ProfitMilling® monitors several vital cutting and machine characteristics.
The ProfitMilling® toolpath manages chip load and side-cutter force in the calculation of toolpath while keeping the engagement angle and material removal rate within a specific range.
It also incorporates dynamic feedrate changes throughout the toolpath and takes advantage of toolpath optimization for specific machine capabilities.
How to Program Using ProfitMilling?
Double or triple tool-manufacture recommended feed, speed and surface speed in MMPT or IPT. Adjust to specific tool wear / performance needs.
For steel, titanium and other hard metals, use a radial engagement between 27 - 37 degrees. For softer materials, use a radial engagement just under 90 degrees. Most parts can be cut a depth of two times the tool diameter.
Whenever possible, use tools with a high flute count. Coolant is generally discouraged, as its use can increase thermal shock on the cutting edge. The ProfitMilling® toolpath puts most of the generated heat into the chip and away from the part and tool. High pressure air may be helpful, as it aids in chip evacuation.
Check your machine's control settings. The geometry "look-ahead" or corner-control setting may adversely affect cycle times. Ensure that the requested feedrates are being obtained.