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Complex free-form surfaces

6.1

6.1 Special functions for free-form surfaces

When machining free-form surfaces, surface quality is the top priority. This calls for a corre-

spondingly high level of accuracy for the CAM data with small tolerances and a large number of

intermediate points.

The large number of points results in even distribution, thereby ensuring a high level of accuracy

and an extremely smooth surface. The integrated high speed setting cycle (CYCLE832) ensures

a high machining speed. This cycle is responsible for activating all the functions that are required

for milling free-form surfaces. This includes the Look ahead function featuring smoothing and jerk

limitation, which anticipates a configurable number of traversing blocks so that the machining

speed can be optimized.

In addition, feedforward control has been implemented to ensure that machining is free from fol-

lowing errors. This is supplemented by the COMPCAD online compressor, which is specifically

recommended for free-form surface milling applications. This brings together a sequence of G1

commands in accordance with the tolerance set in CYCLE832 and compresses them into a

spline that can be executed by the control directly.

Key functions for machining free-form surfaces:

 High speed settings CYCLE832,

as optimum data compression within the tolerance band, combined with feedforward control

and jerk limitation, can be set for the required surface finish without contour deviation.

 TRAORI,

as it has an integrated 5-axis transformation feature for all kinds of machine kinematics,

enabling the tool to be perfectly oriented in relation to the surface so that no contour or sur-

face defects can occur.

 VCS,

as maximum accuracy is required in conjunction with extremely large workpieces. Particularly

applicable when making compression molds and templates in an automotive engineering

context.

 Integrated process chain from generation in CAD through to execution on the CNC.

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