Putting you on the right path
ProfitMilling® strategy for 2, 3, 4 and 5-axis roughing cycles allows customers to remove more material in a shorter amount of time. The ProfitMilling® strategy optimizes engagement angle, chip load, lateral cutter force and machine acceleration to achieve optimal results.
What is ProfitMilling?
The ProftMilling roughing strategy is a high-speed material-removal cycle that allows programmers to take a signifcantly deeper, faster and more effcient cut while reducing wear on the tool and machine.
The ProftMilling algorithm (which is a unique, patent-pending method for calculating toolpath) was developed to take both tool-engagement angle and constant step-over into consideration.
Rather than controlling just one parameter, ProftMilling monitors several vital cutting and machine characteristics.
The ProftMilling toolpath manages chip load (the thickness of a chip formed during the machining of the material) and side-cutter force in the calculation of toolpath while keeping the engagement angle (the angular measurement of the edge of the cutting tool that is in contact with the material being removed) and material removal rate within a specifc range.
It also incorporates dynamic feedrate changes throughout the toolpath and takes advantage of toolpath optimization for specifc machine capabilities, such as machine acceleration and deceleration.
ProftMilling removes the restrictions of traditional roughing toolpath. Sharp corners are replaced with smooth toolpath blending and transitions. Trochoidal slotting strategy is applied to replace full-width slotting, and instead of employing constant centerline feedrate, dynamic feedrate changes are incorporated throughout the toolpath. By maintaining a very consistent tool load, so as not to exceed a specifed amount, the feedrate is easily optimized to maximum potential. ProftMilling also takes advantage of corner picking, or the practice of removing less material in corners, which eliminates chatter and keeps a constant tool-engagement angle. Likewise, it optimizes transitional moves with small Z-directional lifts to prevent the tool from dragging on the machined surface and thus reduce tool drag. As a result of these enhancements, a signifcantly deeper, faster and more effcient cut can be made while dramatically reducing cycle time because the toolpath keeps the tool operating near its capacity
75% cycle-time reduction compared to traditional concentric pocketing
500% increase in tool life compared to traditional concentric pocketing
Decreased programming time
Reduced energy consumption due to decreased machine-tool cycle time
Productivity improvements, even with light and medium-duty machine tools
Available for 2 ½ ,3, 4, and 5-axis roughing cycles
What are the benefits to manufacturers?
Manufacturers are constantly challenged with intense competition and are continuously in search of new means with which to produce quality parts within shorter periods of time, and at reduced cost.
The benefits of the ProfitMilling cycle are a reduction in machine-tool cycle times, increased tool life, decreased programming time, reduced energy consumption and significant productivity improvements - even with light and medium-duty machine tools. Test results have shown that ProfitMilling typically reduces cycle time by 75% compared to a traditional concentric roughing strategy.
How Does ProfitMilling® work?
ProfitMilling is a high-speed roughing cycle that allows you to take a significantly deeper cut of the tool and increase the cutting feed. Rather than controlling just one parameter, ProfitMilling® monitors several vital cutting and machine characteristics.
The ProfitMilling toolpath manages chip load and side-cutter force in the calculation of toolpath while keeping the engagement angle and material removal rate within a specific range.
It also incorporates dynamic feedrate changes throughout the toolpath and takes advantage of toolpath optimization for specific machine capabilities.