Feed Rate Optimization
Cut parts faster, improve surface finish, & reduce tool wear without altering the path trajectory
VERICUT is a true knowledge-based machining system. Through the simulation process, it learns the exact depth, width, and direction of each cut. And it knows exactly how much material is removed by each cut segment. With that knowledge, motion is divided into smaller segments and the best feed rate for each cutting condition encountered is assigned. It then outputs a new tool path, identical to the original but with improved feed rates. It does not alter the route of the tool path. Two independent modules are available for optimizing feed rates: OptiPath and Force.
VERICUT’s optimization modules automatically modify feed rates based on the cutting conditions to make your programs more efficient, while also extending tool life and improving surface finish!
OptiPath uses standard machining formulas, setting the feed rate based on the user’s desired volume removal rate, chip thickness, and surface speed. A setup wizard prompts for cutter settings as you simulate machining operations. Essentially, you add intelligence to the cutter. All the settings for that cutter are stored in an optimization library. You define the settings once. Then each subsequent time you simulate machining operations with that cutter in the same material and machine the motions can be instantly optimized.
OptiPath also features a “learn mode” for creating the optimization library with no setup required. For each cutter, OptiPath finds the maximum volume removal rate and chip thickness and uses them to determine the optimization settings for the cutter.
Learn more about OptiPath.
Force uses material properties associated with the workpiece and cutting tool material, plus cutting edge geometry and VERICUT’s simulated cutter contact conditions to predict cutting forces and chip load. Detailed charts can be viewed in order to determine potential problems in chip load, force, spindle power and torque. The software then automatically adjusts the feed rate to stay within desired force, chip load and power limits. Force predicts cutting conditions using a proprietary set of material coefficients that account for the shear-strength of the workpiece material and the effects of friction and temperature.
The material data is created from physical machining characterization tests and does not rely on extrapolating from finite element theoretical results.
Learn more about Force.
Which is better?
Both methods produce optimized feed rates to achieve similar benefits: reduced cycle times, better surface finish, less tool wear, etc. Force excels in difficult-to-machine materials, and especially complex multi-axis cuts such as 5-axis flank milling. Once a workpiece material is characterized, it can be used for a broad range of cutters and machines in future machining operations. OptiPath does not use a materials database and relies on the user’s machining knowledge to set his desired machining conditions. It is effective when ideal cutting conditions are known for each cutting tool, material and machine.
Questions? Please contact us.