{"id":14522,"date":"2020-04-28T17:05:10","date_gmt":"2020-04-28T17:05:10","guid":{"rendered":"https:\/\/www.moduleworks.com\/?p=14522"},"modified":"2020-09-08T11:54:43","modified_gmt":"2020-09-08T11:54:43","slug":"moduleworks-latest-development-for-ultra-precision-machining","status":"publish","type":"post","link":"https:\/\/www.moduleworks.com\/de\/moduleworks-latest-development-for-ultra-precision-machining\/","title":{"rendered":"Latest ModuleWorks Developments for Ultra-Precision Machining"},"content":{"rendered":"\t\t
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To keep pace with the fast changing requirements of the optics market, ModuleWorks has added several new features to its ultra-precision machining core. These new features advance the overall strategy of combining conventional CAM machining patterns like roughing, drilling and chamfering with the needs of ultra-precision machining.<\/p>

The input data for ultra-precision machining are different to those in standard CAD\/CAM systems. Optical features are often defined by formulas, polynomials and point clouds. ModuleWorks accepts a mixture of these different data types as input for toolpath generation\u00a0and now also accepts so-called secondary drive surfaces that provide optional control of the tool orientation motion. This new feature smooths out vibrations and orientation changes for improved multi-axis turning and milling of complex workpieces.<\/p>

A spiral morph\u00a0pattern has been developed for manufacturing non-rotational symmetrical\u00a0molds for lenses. The morph pattern delivers enhanced precision by generating a continuous toolpath without abrupt changes in the tool direction.\u00a0<\/p>

Furthermore,\u00a0new\u00a0application-driven projection methods ensure optimal pattern distribution onto\u00a0surfaces\u00a0for manufacturing parts within required form and positional tolerances. In addition, new projection methods enable\u00a0inside and outside diamond turning.\u00a0\u00a0\u00a0<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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New Ultra-Precision Machining Features<\/h3>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
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Spiral Morph Pattern<\/h4>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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This new toolpath\u00a0pattern enhances the precision of non-rotational symmetrical parts.\u00a0This feature is in high demand for manufacturing molds for elliptical lenses where\u00a0a\u00a0continuous toolpath from the outer elliptical contour to the circular\u00a0center of the parts\u00a0is needed.\u00a0The spiral morph pattern creates a spiral toolpath\u00a0which\u00a0morphs\u00a0the elliptic outer\u00a0contour\u00a0into a circular one in the center.\u00a0Users benefit from a\u00a0continuous\u00a0toolpath\u00a0without\u00a0abrupt change\u00a0in the\u00a0tool direction, which enhances precision.\u00a0\u00a0<\/p>

The algorithm interpolates between the outer and inner input curves, which can both be arbitrarily formed. You can also control other parameters\u00a0such as the\u00a0cutting direction\u00a0and\u00a0the\u00a0distance between adjacent\u00a0toolpaths\u00a0(step-over).\u00a0<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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Point Data Import<\/h4>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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ModuleWorks provides new types of toolpath-generation based on Point Data Import which come from measurement devices like touch probes, interferometer or are generated by software systems like Matlab.
Since optical free-form surfaces are often described by formulae, NURBS surfaces or also point
data, modern CAM-systems for Ultra Precision Machining must support all these different sorts of surface description. In terms of Point Data, new data formats are now supported. Besides the already supported import of xyz-data, the ModuleWorks core now support the import of:<\/p>

  • Point profile<\/strong> allows the input of a profile which means points in xz-plane. It can be imported as xz- or txt-file. A point with x=0 will generate a closed surface in the center.<\/li><\/ul>
    • Radial point grid<\/strong> allows the input of radial point grids which are xzc-profiles. Radial points can be imported as xzc- or txt-file format. C is the angle in degrees which is measured counterclockwise in workpiece coordinate system. Angle step or radial point distance can be irregular. Every point must have a unique position.<\/li><\/ul>

      Users can combine various kinds of surface inputs together and tailor their toolpaths. A typical example can be to first calculate a toolpath using point cloud or parametric surface. The user can tailor this toolpath in a second step by using NURBS surface to specify which areas of the part should not be machined. Additionally a secondary surface can be chosen to specify the orientation of the cutting tool during machining.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t

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      Point and Line Projection<\/h4>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t
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      New projection methods are now available for projecting toolpath patterns onto\u00a0the\u00a0surface of a part.<\/p>

      Standard methods use Z-axis projection to project a pattern from top to bottom onto a surface, but z-axis projection does not deliver\u00a0appropriate\u00a0toolpaths\u00a0for all types of part.\u00a0ModuleWorks has developed application-driven solutions that\u00a0complement the Z-axis\u00a0projection with two\u00a0new\u00a0methods. Each method is appropriate for specific\u00a0part shapes. The\u00a0three projection types are:<\/p>

      • Z-Axis Projection<\/strong>: the standard projection method.\u00a0The toolpath pattern is generated in the\u00a0xy-plane and projected along the z-axis onto the surface.<\/li><\/ul>
        • Point Projection:\u00a0<\/strong>The\u202ftoolpath\u202fpattern is generated on a plane which is parallel to the\u00a0xy-plane at a specified height and then projected towards (or away) from a point on the z-axis at a given height.\u00a0Its preferred application is,\u00a0for example, for\u00a0strongly curved\u00a0lens surfaces which\u00a0are not completely covered\u00a0by Z-axis projection. Point projection can also be combined with the spiral morph pattern to manufacture asymmetric\u00a0molds such as D-segments.\u00a0<\/li><\/ul>
          • Line Projection:<\/strong>\u00a0A helix\u202ftoolpath pattern (axis on the z-axis)\u202fis generated\u202fand radially projected towards (or away) from the z-axis.\u00a0It is predominantly used for\u00a0tube-shaped parts.\u00a0It generates a revolving pattern\u00a0which can cover either the\u00a0inner or outer surface.\u00a0A typical application area\u00a0is turning\u00a0vertical walls on an asymmetric\u00a0die\u00a0using\u00a0inside and\u00a0outside diamond\u00a0turning.\u00a0<\/li><\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
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            \n\t\t\t\t\t\t\t\t\t\t\"Z-Axis-Projection\"\t\t\t\t\t\t\t\t\t\t\t
            Z-Axis-Projection<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t
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            Point Projection<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t
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            \n\t\t\t\t\t\t\t\t\t\t\"Line-Projection\"\t\t\t\t\t\t\t\t\t\t\t
            Line-Projection<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"

            To keep pace with the fast changing requirements of the optics market, ModuleWorks has added several new features to its ultra-precision machining core. These new features advance the overall strategy of combining conventional CAM machining patterns like roughing, drilling and chamfering with the needs of ultra-precision machining. The input data for ultra-precision machining are different […]<\/p>\n","protected":false},"author":11,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"inline_featured_image":false,"site-sidebar-layout":"default","site-content-layout":"default","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","ast-disable-related-posts":"","theme-transparent-header-meta":"default","adv-header-id-meta":"","stick-header-meta":"default","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"default","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"ast-content-background-meta":{"desktop":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"footnotes":""},"categories":[37,32,16],"tags":[],"class_list":["post-14522","post","type-post","status-publish","format-standard","hentry","category-additive-process-technologies","category-digital-manufacturing","category-news"],"acf":[],"_links":{"self":[{"href":"https:\/\/www.moduleworks.com\/de\/wp-json\/wp\/v2\/posts\/14522","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.moduleworks.com\/de\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.moduleworks.com\/de\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.moduleworks.com\/de\/wp-json\/wp\/v2\/users\/11"}],"replies":[{"embeddable":true,"href":"https:\/\/www.moduleworks.com\/de\/wp-json\/wp\/v2\/comments?post=14522"}],"version-history":[{"count":9,"href":"https:\/\/www.moduleworks.com\/de\/wp-json\/wp\/v2\/posts\/14522\/revisions"}],"predecessor-version":[{"id":15405,"href":"https:\/\/www.moduleworks.com\/de\/wp-json\/wp\/v2\/posts\/14522\/revisions\/15405"}],"wp:attachment":[{"href":"https:\/\/www.moduleworks.com\/de\/wp-json\/wp\/v2\/media?parent=14522"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.moduleworks.com\/de\/wp-json\/wp\/v2\/categories?post=14522"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.moduleworks.com\/de\/wp-json\/wp\/v2\/tags?post=14522"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}