CAM software and tools: can your CNC machining be more efficient?

The relationship between CAM (Computer-Aided Manufacturing) software and tool consumption is a critical factor for CNC machining efficiency. CAM doesn’t just generate toolpaths; it directly influences how they interact with the material and the machine, impacting tool life. By optimizing parameters such as feedrate, depth of cut, and more, CAM systems can dramatically reduce tool consumption, ensuring high-performance, optimized machining.

Here we are going to explore a bit more the relationship between tools, machine and CAM software settings to get out the most from each machining.

Toolpath generation: what to consider first

Before setting a toolpath in a CAM, there are several elements that need to be considered and for which a good set-up really makes the difference in machining performance and results. We are talking about:

• Blank geometry
• Material type
• Characteristics of the selected tool (like tool geometry, tool material, coverage)
• Cutting parameters (depth of the steps, quickness etc.)
• Working strategy (milling, turning, finishing etc.)

All of the above-mentioned elements strongly influence tools performance as heavily influencing mechanical stress as well as tool consuming. A not properly designed path can easily generate vibrations, variable loads and unstable conditions, accelerating tool deterioration.

Core strategies to apply to reduce tool consumption

To reduce tools consumption is highly recommend implementing advanced strategies such as trochoidal strategy, 5-axis or high-speed machining. Those strategies provide unvaluable benefits allowing operators to:

• Distribute the load evenly
• Maintain constant engagement angles
• Limit heat generation

Actually, the most advanced CNC software like RhinoNC CAM developed by CIMsystem, come equipped with smart modules, able to automatically suggest the right tools to be used according to machine, type of machining and material or indicate the most suitable parameters based on the chosen tool. Very often, these software archive and save the selected settings to optimize production times for subsequent identical machining operations. The contribution offered by the automation of the CAD and CAM solution helps avoid critical conditions such as interrupted cuts, micro-cracks, or overloads.

Finally, most of the CAM software offer 3D model preventive analysis, toolpath simulation and collision check, to avoid crushes and reduce movements which affects tools life conditions and duration. These operations are fundamental for safe production and predictable outcomes, especially for 5-axis CNC machining.

Interactions between CAM software and CNC machine: how to optimize performance

As mentioned, thanks to simulation operations, effective CAM solutions can estimate in advance when and for how long tools and material will be in contact, predicting tool thermomechanical load and the expected erosion. These predictions allow operators to perform related changes and optimization such as:

• Schedule preventive tool changes
• Optimize the sequence of machining processes
• Integrate control macros directly into CNC machine programming

The most advanced CAM are also able to interact with wider ERP and controlling IT systems, recording data and updating strategies for further machining, improving overall efficiency. Furthermore, when integrated with most advanced digital systems such MES (Manufacturing Execution System) and PLM (Product Lifecycle Management), CNC software solutions can work synergistically with specific tool management modules tracking tool data like usage history while estimating remaining tool life. This information is essential for workflow optimization.

How can you benefit of CAM software appropriate strategies: A practical case

When milling a mold made of high-hardness steel, erosion of carbon made tools in critical. Bu using advanced milling such as trochoidal milling, it is possible to:

• Reduce CAM toolpaths stress on the cutting edge
• Subdivide the most stressed areas to be machined step by step
• Improve process predictability to avoid sudden breaking

Interaction with software and machinery allows operators to activate alerts or automatic replacements with paring tools, reducing unplanned downtime and keeping on time the overall manufacturing process. However, it is relevant to notice that CNC tools portfolio is very wide in the modern area, with the right tools built for every machinery and material. Therefore, we highly recommend to follow tools manufacturers specification for choosing the right CNC equipment for the best productivity.

Challenges and predictions in CAM industry

Despite the well-known CAM capabilities, a wide range of users is still underestimating the importance of solutions integration. That’s mainly because advanced integrated CAM may also bring some challenges such as:

• Integration between old machines tool and old IT infrastructure
• A not common standard for the nc code
• Unreliability of data collection

However, there are plenty of new opportunities that can be provided by AI and machine learning, so don’t forget to keep an eye on technology innovation for a reliable, automated and even more sustainable production.

CIMsystem, is a CAM software manufacturer with 30 years of programming experience in an international environment providing cutting-edge solutions in dental and industrial manufacturing. Our experts are able to develop post-processors on demand for innovative and flexible solutions, with system integration as one of our top priorities.

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