Challenges in the machining process
Cost pressure combined with increasing flexibility and consistent quality at a high level are currently the biggest challenges in machining production processes. This is due to the cutting parameters defined in the CNC program, which are retained unchanged during machining. In practice, reliable CNC planning involves conditions that are not 100% predictable in advance, and which may impair the machining process. Material fluctuations or tool wear may alter the cutting conditions during the production process. In order to maintain high performance, the cutting speed and feed rate may require supervision and adjustment. This depends on the material and mainly applies when machining difficult-to-cut materials such as gray cast iron, cast iron or nodular cast iron.
TDM iCut: The unique software solution for optimizing the machining process
TDM iCut monitors and optimizes the machining process using adaptive feed control. The software is intelligent and intervenes – in real time. The software measures the spindle power up to 500 times a second and automatically adjusts the feed rate to the actual cutting conditions. With TDM iCut, tool breakage and overuse can be avoided, and unplanned downtimes in shopfloor operations can be prevented. This results in the tools being used for longer, which can lead to a permanent cost reduction. In addition, a significant runtime reduction of 12% on average per controlled tool is possible, and the overall production time is also reduced.
Long-term production optimization and longer tool service life
Our users enjoy wide-ranging machine improvements: With the TDM iCut software solution, it is possible to reduce your production time by up to 25% in individual milling and drilling programs, and therefore achieve permanently high savings after just one installation. Our customers' experiences show that using TDM iCut results in an ROI in less than six months. The adaptive feed control also offers long-term benefits for the tool inventory: TDM iCut learns a maximum power value for each tool use in an NC program, which is not exceeded during machining. The "learned" tools and spindles are therefore protected against overload. Improved medium chip removal and long-term optimization of machining is possible. This also gives the tools a longer service life, which in turn reduces tooling costs in the long term.
Who benefits from adaptive feed control with TDM iCut?
Typical users of TDM iCut include production managers, machine operators as well as machine manufacturers. The software is available for Siemens and Heidenhain controllers. TDM iCut is ideal for applications such as roughing, milling or interrupted cuts. TDM iCut can also be used for rough and semi-finished machining of geometries with constantly varying material deposits. TDM iCut is a solely software solution, with no additional hardware required. Only one installation is required per machine.
