NCG CAM Adaptive Area Clearance Machining - A Trochoidal Milling Strategy - Quickgrind and NCG CAM

Adaptive Area Clearance in NCG CAM Software

Many CAM software packages offer Trochoidal Milling, using various names. NCG CAM uses an advanced Trochoidal strategy called ‘Adaptive Area Clearance’.

Adaptive Area Clearance is included in NCG CAM as standard = No Extra Cost

Most other CAM software packages charge additional prices for this as a separate module. Some charge almost the same price for their Trochoidal Milling module, as is charged for the complete NCG CAM Basic License!

In NCG CAM, this cutting technique is aimed towards high speed machining with solid carbide cutters. It provides the ability to safely cut using the full length of the flute at the optimum cutting speed for the material and part. Tool wear is spread evenly, cutting more on the flute than the bottom of the cutter; deflection and vibration is minimised by maintaining a constant load on the cutter. The machine runs at the optimum speed without exceeding its limits at an isolated point. The technique is particularly suitable for cutting hard materials and also electrode manufacturing.
 

The strategy automatically adjusts the toolpath for efficient and safe machining, improving cutting conditions and applying a more consistent load. In some applications, higher machining speeds may be achieved.
 
As well as significantly improving tooling life, Adaptive Area Clearance can reduce machining time up to 40% over conventional roughing.
The linking order is very important, so this is done directly after the passes are calculated.
This strategy firstly clears in deep layers, using the full flute length of the tool, following the 3D form.
The shallow levels are cleared last, as terraces, so maximising the efficiency of the tool.

This strategy can be used for:

Machining cores - It uses the shape of the original stock to maximum effect when machining from the outside inwards, towards the finished shape of the part.
Rest Machining where a previous larger tool has removed most of the material, but a smaller tool must be used to access the finer details. When a previous toolpath is selected, this strategy takes account of the stock after the selected machining operations and limits itself to the non-machined areas.

Examples of Quickgrind Tooling to Use for Adaptive Area Clearance

The Mirage variable flute variable helix solid carbide coated end mill is designed for machining Stainless Steels and Super alloys as shown in the table below. Capable of normal machining and trochoidal strategies it’s tough substrate, geometry and coating give this tool a high resistance to wear and reduced vibration.

When using trochoidal or Area Adaptive Clearance strategies, we encourage clients to use all the flute length and can supply tools with longer than normal flute lengths as required. Higher speed and feed is matched with full flute engagement and smaller width of cut resulting in reduced cycle times and excellent tool life. We also offer these tools with chip breakers to reduce the size of the chips and aid better swarf handling.
 
Available with 4 to 7 flutes and from 2.00mm to 32.00mm Diameter in various overall and flute configurations.

The QCut range of variable flute, variable helix Solid Carbide coated end mills are designed for machining a wide range of materials including H13, P20 and D2 tool steels. Whether using normal or trochoidal/Area Adaptive Clearance milling strategies this tool performs very well providing excellent tool life and high resistance to wear and vibration.

Using this recipe of tool combined with trochoidal milling where widths of cut (ae) of 10% or more are possible and full flute length engagement, this cutter greatly reduces cycle times with increased tool life. If we then add chip breakers to the design this tool for pocket milling the results are outstanding.

Available in 4 or 5 flute versions with various lengths of flute to enable full flute engagement.


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