Page 1

Vero Software LimitedHadley House, Bayshill Road, Cheltenham, Gloucestershire, GL50 3AW, UK

:Waveform Event

Page 2

• Introduce Edgecam Waveform Technology• Edgecam Waveform Testing• Where to find Edgecam Waveform data• Q&A

Waveform Agenda

Page 3

Unlocking Your Machines Potential

Page 4

Higher Feedrates!

Maximum RPM!

At deeper Depths!

Unlocking Your Machines Potential

Page 5

How deep can I cut?

How fast can I cut?

How much stepover can I take?

Think About Every Part You’ve Cut

Page 6

Deeper…

With a larger stepover…And FASTER!!!

At higher RPM…After all, if you cut in a straight line, you can machine …

WHY?

(video)

Page 7

Traditional Toolpath Review

Page 8

Straight line vs. corners• The challenge with traditional toolpath / shape offset machining

50% of Cutter 100% of Cutter

Material Engagement

10mm End Mill at 50%=5mm 10mm End Mill at 100%=10mm

Page 9

180 Degree EngagementFeedrate Override!!

Page 10

Traditional vs Waveform

Page 11

WaveformThis new roughing strategy is a high speed machining technique that maintains a constant tool cutting load by ensuring the tool engagement into the material is consistent. The tool path moves in a smooth path to avoid sharp changes in direction which maintains the machine tool’s velocity.

Edgecampedia

acceleration =change in velocitytime

Page 12

Waveform Pattern• Helical plunges into pocket• Imitates straight line cutting• Maintains constant chip load• Reduces intermittent cuts• Tool is engaged with material longer without lifting• Reduces Cycle Times• Smooth tangent toolpath

•Reduces wear and tear on tools, holders, and machine

•Works with 2D or 3D Roughing

Edgecampedia

Page 13

• Deeper Depth of Cut (DoC)• Use full Flute Length

• Manages Width of Cut (WoC)

• Controls Chip Thickness • Generating Faster Feedrates

•Constant Feedrate • Superior Speeds

•Consistent Tool Load

Waveform Properties

Edgecampedia

20% WoC

DOC = 2.5 x Tool Diameter

Page 14

• Maintains consistent material removal by adjusting width of cut

• Maintains chip thickness and chip load

• Concave areas • Width of cut decreased

• Convex area• Width of cut is increased

Automatically Adjusts

Edgecampedia

Page 15

• Links are aware of rapid and High Feedrates

• Waveform uses fastest method

• Localized areas stay at depth

• Long Links retract and rapid

Waveform Links

Edgecampedia

Page 16

• Tapered Helical Plunge•3 Degree Taper

• Percent Speed adjustment for Helical Plunge

• Optimized Mill Type•Alternates Climb/Conventional

• Improvements to Arc Tangency

Waveform Enhancements

New in 2012 R2

Page 17

• Uses standard Roughing Cycle

• Simple Interface

• 3 Modifiers To Adjust

• Minimum Radius can also be used

Waveform Ease of Use

Edgecampedia

Page 18

The Hard Part

“Not on my machine you don’t!!”•Finding machine time•Test straight line test cutting

• Run until tool breaks and back off 20%

•Add Test Data in Waveform Cycle•DO NOT Adjust Feedrate Override during cycle

• Slowing down will burn up cutter

“Wow, I didn’t know my machine could do that!!”

Getting Started

Page 19

Tool Size RPM Feed DOC %Step Cycle Time

16mm 2600 1000mm/Min 5mm 30% 63 min

Machine: Mazak Vertical Centre Smart 430 A

Material: P20

Tooling Provided Courtesy of Sandvik

Tool Size RPM Feed DOC %Step Cycle Time

16mm 5000 3000mm/Min 20mm 18.5% 18 min

Waveform Test

Waveform Toolpath

Traditional Toolpath

Cycle Time Reduce By:45 min = 71%

Page 20

Tool Size RPM Feed DOC %Stepover Cycle Time

.500 4FL .06R

1500 16 ipm .125 30% 42:32

Machine: Mori Seiki MV-653

Material: 4140 Rc: 28-36

Tooling Provided Courtesy of Sandvik

Tool Size RPM Feed DOC %Stepover Cycle Time

.500 4FL .06R

10,000 196 ipm 1.00 18% 4:15

Waveform Test

Waveform Toolpath

Traditional Toolpath

Cycle Time Reduce By:38 min = 90%

Page 21

Waveform Live

Page 22

Waveform Data

Page 23

Waveform Data Sheets

Page 24

Questions

Page 25

I ran Waveform at the same feeds and speeds with my usual settings and it wasn’t any faster.

Why?

Waveform was designed to cut significantly faster and deeper than traditional toolpaths. If you run at the same parameters (Spindle Speed, Feedrate, Axial Depth of cut, Radial Depth of Cut) as with traditional toolpaths, you are driving a Ferrari at Yugo speeds. Run Waveform toolpaths to their capability and it will be unbelievably faster.

Questions

Page 26

Does Waveform require specialized tooling?

Reviewing your entire process, such as tooling, work holding, and coolant will bring further cycle time benefits. When using your existing tooling, Waveform users will see improvements in cycle time, tool life, and machine maintenance cycles.

Questions

Page 27

Does Waveform require higher-end/high-speed machines with expensive options?

No, some of the largest performance increases to date have been realized on older basic machines. Waveform toolpaths can be run much faster and deeper than any traditional toolpaths due to constant tool load.

Questions

Page 28

I’m a job shop and I don’t run production. Most parts are one off’s. How will I benefit

from Waveform?

Waveform users can quote lower machine rates compared to non users or charge the same rates and run more hourly jobs per week/month/year. Not to mention extended tool life from constant tool load and reduced machine maintenance cycles.

Questions

Page 29

Will I only see cycle time improvements in Aluminum parts?

Actually, Waveform is even more impressive in hard materials. Overloading the tool is much more severe in harder materials than in softer materials. Since Waveform never overloads the cutting tool, hard materials can be cut at very aggressive material-removal rates.

Questions

Page 30

Why doesn’t Waveform adjust feedrates?

Other CAM systems that provide toolpath similar to Waveform, do no adjust engagement in convex and concave corners. This giving Waveform an upper hand. Since constant chip thinkness is calculated through corners, no feedrate adjustment is required. Waveform either reduces it’s % stepover or increases depending on the cut.

Questions

Page 31

: Thank you

Questions?