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QuickMilling - Operation Types

In this Article:
QuickMilling - Operation Types

QuickMilling - About Operations

QuickMilling - Geometry Types
QuickMilling - Geometry Classifications
QuickMilling - How to Define Operations

QuickMilling - Roughing Operations

QuickMilling - Rough Smoothflow Operation

QuickMilling - Rough Offset 2D Cut Operation
QuickMilling - Rough Lace Cut Operation
QuickMilling - Rough Plunge Cut Operation
QuickMilling - Rough Pre-Drill Cut Operation

QuickMilling - Finishing Operations

QuickMilling - Offset 3D Cut Operation

QuickMilling - Lace Cut Operation
QuickMilling - Angle Limiting Cut Operation
QuickMilling - Drive Curve Cut Operation
QuickMilling - Z Level Cut Operation
QuickMilling - Pencil Cut Operation
QuickMilling - Flow 3D Cut Operation
QuickMilling - Engrave 2D Cut Operation
QuickMilling - Bulge Cut Operation

QuickMilling - High Speed Machining (HSM)

QuickMilling - More about HSM

QuickMilling - HSM SmoothFolw Cut Operation
QuickMilling - HSM Offset 2D Cut Operation
QuickMilling - HSM Lace Cut Operation
QuickMilling - HSM Flowing Cut Operation

QuickMilling - Operation Types

(CAM Manager) Operations > > Insert > QMill (CAM Level)

ZW3D QuickMilling is a set of tool path operations based on internally calculated STL triangulated representations of your
part geometry. The list of QuickMilling operations is provided in the table below.

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QuickMilling Operations
Roughing Finishing High Speed Finishing

Smoothflow Rough Offset 3D HSM Smooth Flow

Offset 2D Rough Lace HSM Offset 2D

Lace Rough Angle Limiting Cut HSM Lace

Plunge Rough Drive Curve HSM Flowing

Pre-Drill Rough Z Level (Side)

Pencil

Flow 3D

Engrave 2D

Bulge Cut

QuickMilling - About Operations

The QuickMilling method improves upon the standard ZW3D milling operations in the following ways:

Accuracy
Tool paths are "gouge-free" and are based on user specified tolerances.

Robustness
Any input data can be machined.

Tolerant
Supports degenerate and incomplete part geometry because ZW3D QuickMilling is not based on surface normals.

Fast
Tool path calculation time is greatly reduced for medium to complex parts. High Speed Machining (HSM)
techniques are also supported.

Intelligent
Tool path calculations are cached for reuse. Cached data offers various ways of reuse such as common cache
folders shared by different machines or threads and restarting tool paths based on cached data.

These tool path operations use the following:

Frames, speeds and feeds

Link parameters
Lead in/out parameters
Limiting containment and clipping
Adaptive feed control (AFC) and other advanced options

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QuickMilling - Geometry Types

Geometry for QuickMilling operations can be specified with the use of CAM components or surface and solid CAM
features. Stock can be defined explicitly using a CAM component whose Class attribute is set to stock. Refer to
the CAM Component Manager for more information.

You can also set the CAM Class attribute for a part using the Part Attributes Form while at the Part Level. CAM will
recognize the component as Stock automatically. The following table highlights the geometry classifications recognized
by QuickMilling.

QuickMilling - Geometry Classifications

Part
Refers to the part geometry to machine. Currently QuickMilling supports CAM Components of class "part" and
CAM features of class "solid" or "surfaces." For the QuickMilling flow cut and drive cut operations, in addition to
"Part" geometry, guide curve/projection curve geometry is required. This geometry can be CAM features of type
"Profile." This feature (geometry) needs to be picked explicitly for individual operations. Profiles - For HS
Flowing and Drive Curve cuts, in addition to "Part" geometry, guide curve and projection curve geometry is
required. This geometry can be CAM features of type "profile". You need to explicitly pick the feature (geometry)
for individual operations.

Containment
CAM Feature Groups (class=profile, type=contain) may be used to limit the tool path. This is an optional
input supported by all QuickMilling operations.
Important Note from the developer: As much as possible, try to avoid using containment in roughing!
Roughing should always be contained ONLY by stock.
The "Enhanced" roughing with containment will only endanger the milling process.
QM has a very complex way of analysing the milling evolution and keeps the stock always updated to
judge how to safely mill complex parts. Any kind of limiting its way of approaching this can endaner
milling and break the tool.
Examples could be:
1. Using interfering XY Limiting.
2. Using interfering holder collision.
3. Using interfering flute length collision.
4. Forcing lead moves to be contained in containment.
All this dramaticly reduces roughing safety. QM likes a part and a stock only and somehow generates paths
that are safe. I believe in this moment is the safest CAM system when roughing.

Stock
Refers to stock geometry information. Currently QuickMilling supports CAM Components of class "stock."

Clamp
Refers to clamp geometry information used to decide avoidance/collision at the time of tool path calculation.
Currently QuickMilling supports CAM Components of class "clamp."

Table
Refers to table geometry information used to decide avoidance/collision at the time of tool path calculation. The
tool path is modified (lead-in/lead-out) if any collision is found. Currently QuickMilling supports CAM Components
of class "table."

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You need to select "Part" and "Stock" for each QuickMilling operation. "Clamp" and "Table" information is
picked-up from the active CAM Setup. The STL data for "Clamp" and "Table" is exported and sent to
QuickMilling via the Operation Descriptor File .

QuickMilling - How to Define Operations

1. In the CAM Plan Manager, right-click on Operations, select Insert and then select the QuickMilling operation
from the form provided. The operation will be added to the manager tree.

2. Select Parameters under the operation you just added and set the parameters using the definition form
provided. Pick Accept when you are done. Each QuickMilling operation uses a unique definition form. They are
shown below under each operation type. See QuickMilling Operation Form Parameters for a definition of each
parameter.

Notice that (undefined) is shown next to Features under the rough operation you just added. This means that
no features are yet defined for the operation.

3. Your CAM features (once you define them) are listed under the Geometry section of the manager tree. Under
Geometry, find the CAM component (i.e., part : name) and expand it (i.e., select to the left of the part) to list
the CAM features currently defined for that component and select one. It will now be listed under Features for the
QuickMilling operation you just created. The (undefined) flag will be removed.

To create a new CAM feature: Again, under Geometry right-click on the CAM component, select Add Feature
and follow the forms and prompts. You will be prompted to select geometry from the graphics window.

QuickMilling - Roughing Operations

Roughing operations use the stock as the primary limiting method and its dynamic shape is of primary concern. Only
components of Type=Stock should be selected for these operations features. See Referencing CAM Features in the
CAM Operations Manager for more information.

Milling conditions for roughing operations are ruled by the tool and machine rigidity not by the surface quality. The main
concern of roughing operations is to remove as much material as possible in the shortest amount of time.

QuickMilling - Rough SmoothFlow Operation

SmoothFlow is a HSM cycle that tries to keep the tool uniformly engaged in material and retract as few times as
possible. There are two flavors: a unidirectional (climb, conventional) version and a zigzag one. The unidirectional
version adds around 10% of overcutting.

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QuickMilling - Rough Offset 2D Cut Operation

Like the high speed offset 2D cut operation, the rough offset 2D cut is used for 2D area clearance of explicitly
defined rough stock. The tool path is first calculated and then projected onto the CAM component geometry.

QuickMilling - Rough Lace Cut Operation

Like the lace cut, the rough lace cut operation is a parallel milling technique controlled by stepping parameters.
It is used for the removal of explicitly defined rough stock. The tool path is first calculated and then projected
onto the CAM component geometry.

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QuickMilling - Rough Plunge Cut Operation

The rough plunge cut operation is a method used to rough out large parts. These can include deep cores and
cavities, high shoulder slots and straight or sloped walls. Those requiring long tools will benefit from this
operation. The process is an axial (vertical) drilling and milling operation performed in a single tool sequence.

QuickMilling - Rough Pre-Drill Cut Operation

The rough drill cut operation is used to create access holes to pocket features on the part to be machined.

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QuickMilling - Finishing Operations

Finishing operations are driven by surface quality (cusp height and tolerance). The shape of the stock does not play a
relevant role and limiting against it is not possible. Finishing offers a wide range of automatic and manual milling
techniques that are particularly well suited for machining part features. See also Reference Tools and Operations.

QuickMilling - Offset 3D Cut Operation

The offset 3D cut operation is used when a smooth and continuous tool path is required in the vicinity of steep
walls, milling in uncut or uncutable places or when milling the entirely part as a whole. This is a finishing
operation designed to achieve an equal cusp condition over the entire tool path.

QuickMilling - Lace Cut Operation

The lace cut operation is a parallel milling technique controlled by stepping parameters. The tool path is first
calculated and then projected onto the CAM component geometry.

QuickMilling - Angle Limiting Cut Operation

The angle limiting cut operation combines several QM motions in steep areas on the part and flat areas. This
improves machining efficiency and surface finish. The cutting can be controlled to just machine the steep areas,
the flat areas, or both.

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QuickMilling - Drive Curve Cut Operation

The drive curve cut operation is similar to the offset 3D cut that starts from a custom set of curves. The starting
curves can be open or closed. In general it is used like the flowing cut for milling along features. The tool path is
first calculated and then can be projected onto the CAM component geometry using the Project Drive Curve
parameter. See QuickMilling Operation Form Parameters for a definition of each parameter.

QuickMilling - Z Level Cut Operation

The z level cut (also referred to as side cut) is used to machine steep walls.

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QuickMilling - Pencil Cut Operation

The pencil cut operation is used to clear corners as a follow up to other QuickMilling operations.

QuickMilling - Flow 3D Cut Operation

The Flow 3D cut operation will "morph" a pattern between pairs of guiding curves. Like the High Speed Flowing
Cut, the curve pick sequence when defining the profile features is very important. The pick sequence is
maintained during tool path calculation. The Flow 3D Cut could follow a Bulge Cut in a tool path sequence.

The cutting pattern can be automatically generated or set between inside and outside patterns. The cutting mode can be
zigzag, unidirectional or top/bottom combinations.

Requirements include a CAM component (class = Part) or CAM features (class = Surface or Solid). Also required are CAM
features (class = Profile) for the flowing projection curves. Optional CAM components (class = Stock, Clamp or Table) are
supported as well as CAM features (class = Profile and Type = Containment).

QuickMilling - Engrave 2D Cut Operation

This is a 2 axis surface engraving operation (i.e., characters on flat parts). You can use ZW3D True Type Fonts for
this operation. After creating the text, use the Explode Text & Dimensions command to create the curves to

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select for the CAM features.

Requirements include a CAM component (class =Part) or CAM features (class = Surface or Solid). Also required are CAM
features (class = Profile and Type = Containment) for the profiles to be engraved. Optional CAM components (class =
Stock, Clamp or Table) are also supported.

QuickMilling - Bulge Cut Operation

This operation creates a network of bulges on a surface using two intersecting curves referred to as a drive curve
(Directrix) and a generator curve (Generatrix). This operation is useful in dispersion networks for automotive
lighting parts or as an artistic hammer-paint effect. The Generatrix is used as a pattern generator that is guided
by the Directrix.

The step size along the Directrix and Generatrix can be specified. The cutting mode can be set to "zigzag" or
"unidirectional" and the depth and % of bulge can also be controlled. Bulge noise (a shift in bulge position) in X,Y and Z
can be specified at appropriate location when necessary.

The requirements for this operation include a CAM component (class = Part) or CAM features (class = Surface or Solid).
Optional CAM components (class = Stock, Clamp or Table) are supported as well as CAM features (class = Profile and
Type = Containment).

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Bulge Cut Tool Path Bulge Cut Solid Verify

QuickMilling - High Speed Machining (HSM)

The ability to deliver mold in the shortest possible time is a major priority for tool makers. Any development that can
provide faster delivery, and at the same time help improve quality should be given serious consideration by the tool
maker. Some of the many strategies for High Speed Machining (HSM) which result in smooth consistent cutting
conditions require the assurance of rapid stock removal. See also Reference Tools and Operations.

QuickMilling - More about HSM

High Speed Machining (HSM) means milling with light depths-of-cut at high feed rates. Milling at lighter depths
was always possible, but high speed makes it practical. Now, light cuts do not have to stretch out the tool path
cycle time. As a result, the machining center can do more.

Through HSM, the machining center can reduce the need for polishing. It can deliver EDM electrodes more efficiently and
can even eliminate the need for EDM in some cases. HSM can let a machining center produce complex tooling
competitively in a single setup.

The smoothness of the machined surface is determined in large part by the height of the cusps between adjacent passes
with a ball nose tool. Take a small stop over and cusp height goes down. Continuity and smoothness are primary
concerns during HSM tool path operations.

ZW3D QuickMilling has taken great care to address geometric related HSM issues. Geometric issues are related to tool
path smoothness, continuity and flowing. Geometric issues are generally accepted guidelines in HSM independent of the
spindle, holder, tools, material or the machining center.

HSM concepts are useful, in general for classic milling as well by increasing machine life, decreasing sound levels,
reducing vibrations (good surface quality) and reducing the machining time.

Following are some of the concepts implemented in ZW3D QuickMilling for High Speed Machining.

Minimize full width cuts

The ordering of each raster area clearance tool path is determined to minimize occasions when the tool cuts full
width. This allows the use of higher feed rates, reducing tool wear and damage particularly during Offset 2D Cut

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operations.

Smart Clearance
As the work piece is machined, this option will retract the tool as little as is necessary before moving across to
another area, rather than retracting above the block each time. This cuts down the number of moves to safe Z
and results in reduced milling times. Smart clearance can be activated by leaving the Clearance parameter of the
QuickMilling Lead In/Out Parameters Form blank.

Offset Area Clearance

Toolpaths calculated using an offset area clearance strategy will contain fewer sudden changes in velocity than
conventional raster machining - an essential requirement for high speed machining during Offset 2D Cut and
Offset 3D Cut operations.

Break after time, length or quantity of material milled

A very important problem that appears in HSM (that will improve any tool path operation in general and roughing
in particular, is the splitting tool paths after time (a popular value is 15 min) or after the length of feed moves.

Cusp Height Control

Maintaining constant material removal volume rate is desirable for High Speed Machining. This condition is
achieved using cusp height control with constant Z finish machining. In general the Offset 3D Cut operation
supports these constraints.

Spiral and Projection Milling

For some shapes, the combination of a spiral strategy with projection milling provides a smooth and continuous
cutting path which is ideal for High Speed Machining.

Leads and Links

By selecting the most appropriate lead and linking strategy it is possible to increase the speed of the tool. This
increases the surface cutting speed, provides even loading on the tool and eliminates dwell marks.

Tangential arc or spline

The tool moves onto and off the job in an arc or smooth spline motion. This allows the tool to move smoothly
without having to slow down. and Lead in and out.

Tool path evaluation

Rapid calculation of toolpaths gives users the ability to modify toolpaths and evaluate a number of different
strategies to ensure that the optimum tool path is selected.

Advanced linking
The High Speed Lace Cut, Offset 2D Cut, Offset 3D Cut and Flowing Cut operations contain routines that allow
advanced continuity and linking. This allows the tool to stay in contact with surface as much as possible.

Smooth Factor
All HSM operations contain a parameter called Smooth Factor (of step) that allows a smooth stage after tool
path construction. This will remove all irrelevant sharp corners inside the tool path.

Classic cycle can have HSM behavior

Classic tool path operations like Lace Cut and Z Level Cut (i.e., Side Cut) do not have the Smooth Factor
parameter but they can be converted to HSM operations using the Corner Radius parameter and smooth links
and leads. Corner Radius reduces the number of potential undercuts in Side Cut. Corner Radius can be
implemented only in operations that have a planar behavior (Lace Cut and Z Level Cut) allowing a smoother tool
path.

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QuickMilling - HSM SmoothFlow Cut Operation

SmoothFlow technology was introduced to machine cavities and pockets safely and efficiently by maintaining
constant material removal during roughing thus extending tool life and reducing machine wear and tear. Higher
feed rates are possible without the risk of tool breakage by reducing the radial pressure on the tool spindle,
essential for optimizing the efficiency of HSM machines.

SmoothFlow motion is softly contoured with corners and tight areas safely milled without full width cuts which
prevents tool and spindle overload. All of these factors are critical for unattended machining to achieve extended tool
life and reduced milling time. ZW3D SmoothFlow gives programmers the confidence to boost productivity with ideal
feed-rates and cutting technology.

QuickMilling - HSM Offset 2D Cut Operation

The high speed offset 2D cut operation is used for 2D area clearance. The tool path is first calculated and then
projected onto the CAM component geometry.

QuickMilling - HSM Lace Cut Operation

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This is a more advanced version of the lace cut operation suited for high speed machining. Like the lace cut, the
tool path is first calculated and then projected onto the CAM component geometry.

QuickMilling - HSM Flowing Cut Operation

The high speed flowing cut operation will "morph" (only a linear interpolation) a pattern between pairs of guiding
curves. Flowing can be along, across or spiral for closed guiding curves. The tool path is first calculated and then
projected onto the CAM component geometry.

Multiple CAM profile features can be defined for this operation. Each feature group is considered one span. The curve
pick sequence when defining the profile feature is very important for this operation. The pick sequence is maintained
during tool path calculation.

Copyright ZWCAD Software Co.,Ltd

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