What is radial engagement
With high-speed machining with the patented ESPRIT CAM-ProfitMilling® roughing cycles for 2.5, 3, 4 and 5 axes, the machining times can be drastically reduced, while at the same time the service life of the tools is significantly extended.
The ProfitMilling strategy combines tool paths that are optimized for high speed, chip thinning with small radial interventions and a full cutting depth with dynamically optimized feed rates, thus guaranteeing a uniform cutting depth and minimal tool pressure throughout the machining process. This leads to higher productivity and lower operating costs.
Compared to traditional milling, ProfitMilling offers the following advantages:
- Reduction of the cycle time by 75%
- Extension of tool life by 500%
Advantages of ProfitMilling
ProfitMilling is a universal high-speed cycle for roughing with 2–5 axes. No additional investments in special tools, fixtures, spindles or machines are required. This specially developed cycle reduces the load on CNC machines, controls and spindles and is therefore also suitable for lightweight machines. ProfitMilling has proven itself extremely well with most materials, but it is particularly advantageous with hard and stable materials such as Inconel and titanium. The combination of optimized tool paths, machining at full depth and small radial engagement results in higher machining performance and shorter machining times. In addition, with this technology, the heat is mainly dissipated to the chips and not to the tool and the workpiece. This behavior extends tool life because the machining area remains cooler.
High-speed machining when roughing with 2.5, 3, 4 and 5 axes
Higher productivity even with machine tools in light and medium-sized designs
Great for most materials
Lower temperatures ensure a longer tool life and a better quality of the machined surfaces
- Reduction of the cycle time by 75%
Extension of tool life by 500%
ProfitMilling uses a patented method for cycle optimization, which ensures a uniform cutting depth and lower tool pressure. In this way, impressive improvements in machining time and tool life can be achieved. Thanks to the tool path optimized for high speed, less strong machine accelerations and abrupt changes of direction are required, which would have a negative effect on the depth of cut and the tool pressure. With a technique for chip thinning, the workpiece is machined at full axial depth and reduced radial width, which enables significantly higher feed rates. So that the programmed depth of cut can be retained during the entire machining process, the actual feed rate in ProfitMilling is dynamically adapted to deviations in the geometry and the tool path. Offset, spiral and trochoidal movements ensure that the machine does not have to be accelerated or decelerated as much. This increases the overall speed, so that the programmed feed rate can be maintained more easily and overall higher material removal rates can be achieved.
Toolpaths optimized for high speed
Chip thinning with small radial engagement and full depth of cut
Dynamic feed to take account of deviations in geometry and toolpath
Opening of cavities by spiral machining for easy removal of the chips
Trochoidal movements to open channels and grooves
Offset of the part boundary when machining "open" areas
Reverse machining from bottom to top for pocket milling and for roughing / residual roughing
Machining takes longer because the machines have to operate at relatively slow speeds to accommodate differences in depth of cut and acceleration that are common in traditional roughing.
- Sharp corners lead to high tool pressure, strong acceleration and jerky movements.
- Full width slot milling overloads the tool.
- Tool engagement with large, varying angles increases the depth of cut.
- A constant feed on the center line leads to different depths of cut.
- Several incremental infeed depths extend the processing times.
Roughing with ProfitMilling
This high-speed cycle allows the tool to rough deeper and faster. This leads to shorter machining times and a longer tool life
- Uniform toolpaths with smooth transitions
- Trochoidal slot milling ensures a constant depth of cut
- Optimized corner machining prevents tool malfunctions and ensures a constant tool pressure angle
- Dynamically optimized feed during machining
- Optimized transition movements with a small increase in Z to avoid grinding the tool
- Machining at full depth reduces or avoids multiple machining operations at incremental infeed depths
- Full cuts reduce several incremental depth steps
- Dynamically optimized feed rate during the cut
Read our ProfitMilling whitepaper to learn more about the benefits of this technology and why ProfitMilling is much more efficient than traditional pocket milling.
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The values recommended by the manufacturer for feed, speed and cutting speed (mm or inches per tooth) can be doubled or tripled. The speed can be adjusted to suit tool wear and specific performance requirements
A radial pressure angle of 27–37% is recommended for steel, titanium and other hard metals. For softer materials, the radial pressure angle should be a little less than 90%. Most parts can be cut to a depth twice the tool diameter
If possible, tools with a large number of cutting edges should be used. Cooling is generally not recommended as it can increase the thermal shock at the cutting edge. With the ProfitMilling toolpath, most of the heat generated is directed to the chips, i.e. away from the workpiece and tool. Compressed air can support the removal of the chips
Check the machine control settings. The setting for the collision or corner control of the geometry can have a negative effect on the machining times. Make sure that the programmed feed rates are achieved.
"Thanks to the use of ESPRIT CAM's ProfitMilling cycle, we were able to reduce the processing time by 65% compared to the time of the competition"
Managing owner, Jostkleigrewe Industrietechnik
We systematically use the ESPRIT simulation module, which shows exactly those processes on the screen that are then implemented on the machine. This avoids collisions and tool damage.
CAM manager, MDL Europe
3-axis mold coreProfitMilling on a DMG MORI CMX 1100V
Kennametal K machiningProfitMilling on an Okuma Genos M460VE
Pressure Regulator Housing MachiningProfitMilling on an Okuma MU 4000v
Talk to our talented team to find out how ESPRIT can help you reduce cycle times, increase machine utilization, and save you time and money.First steps
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