Adaptive Machining Software Reduces Cycle Times

Omative Systems North America debuts its software-based systems for adaptive machining, real-time vibration monitoring and shop floor production management.

Its ACM adaptive feed rate control is designed to reduce cycle time and protect the cutting process by monitoring the load and making real-time adjustments to the programmed feed rate. ACM runs a test on the first workpiece and configures the maximum spindle load for each operation. The user then sets an allowable override of the programmed feed rate, and from there ACM adjusts the feed rate for maximum efficiency based on the learned load value. When cutting conditions are lighter, feed rate is increased and cycle time reduced. Where the load becomes heavier due to unexpected workpiece hardness or thickness, the system reduces the feed, even to below the programmed rate, to protect the cutting tools and workpiece. ACM automatically increases the feed rate to maximum during air cutting, then pauses and lowers the feed immediately prior to entering the material. ACM is said to reduce cycle times by 20 percent, the company says.

ACM can also prolong grinding wheel life by adjusting the feed rate to compensate for ongoing wear. The software can be installed on almost any CNC, including Siemens, FANUC and Heidenhain. Additionally, it receives all its inputs from the controller without the need for external sensors.

The system's VCM Vibration Monitor constantly compares machine and tool vibration against healthy baseline signatures, and issues alerts or shuts off the machine as instructed when values are exceeded. VCM reacts instantly to extreme events and can indicate whether there is internal damage. It also alerts the user to gradual changes in vibration that suggest maintenance is necessary. At the tool level, VCM recognizes broken tools, missing tools or improperly mounted tools, which is critical for companies requiring lights-out operations.