3+2 Roughing

Roughing Strategy for MAX-PAC™ 

Concepts NREC's optional 3+2 Roughing Module enables roughing out of impellers using 3-axis algorithms, keeping a constant tool vector. This strategy optimizes the toolpath to provide constant cutting load, making it suitable for high speed machining. This is extremely helpful for large (>0.5 m) diameter impellers and/or hard materials where roughing using the 5-axis strategies of MAX-PAC is less efficient.

partner-bg-img
  • One-piece shrouded impellers have many advantages over parts produced as an assembly of separate hub and shroud components (or even individual blades), including less raw material and fewer manufacturing process steps. Also, integrally shrouded components avoid heat distortion and have stronger shroud joints compared to fabricated assemblies.

  • MAX-SI includes strategies for pocket roughing, plunge milling, box passes for finish/semifinish, and flow-direction finish milling.

One-piece shrouded impellers have many advantages over parts produced as an assembly of separate hub and shroud components (or even individual blades), including less raw material and fewer manufacturing process steps. Also, integrally shrouded components avoid heat distortion and have stronger shroud joints compared to fabricated assemblies.

MAX-SI includes strategies for pocket roughing, plunge milling, box passes for finish/semifinish, and flow-direction finish milling.

Better, Faster, Cheaper

Manufacturing turbomachinery components is often a challenge due to hard materials, thin blades, tight tolerances, smooth surface- finish requirements, or difficult tool access. Concepts NREC’s MAX-PAC CAM software was built from the ground up to address these challenges. MAX-PAC enables users to produce high-quality components in less time and at lower cost. Compared to other general CAM tools, MAX-PAC is faster to learn, easier to use, and requires less programming and machining time. Its choice of cutting strategies ensures that each client has a solution tailored to their specific milling requirements. The most important attribute of MAX-PAC, however, is its ability to produce higher-quality turbomachinery components.

MAX-PAC Advantages

  • Specialized for turbomachinery production

  • Easy and fast to learn

  • Supports a broad selection of tool geometries

  • Faster machining times with optimized cutting strategies

  • Smooth 5-axis toolpaths for high-speed milling

  • Collision-free toolpaths for difficult geometries

  • Superior surface finish and tight tolerances using a patented flank- or point-milling approach

  • Produces high-quality parts that don’t require hand finishing or other reworking

 

Collision Avoidance

Parts are getting more complicated and manufacturing them can be challenging. MAX-PAC automatically checks the feasibility of machining your part as soon as you program in the tool, holder and geometry. Our patented collision avoidance algorithm quickly determines a smooth, safe trajectory for both the tool and holder through the pocket, or gives a warning if one can’t be found. This saves you time and money by avoiding a lot of simulations and/or test cutting.  

Other CAM systems use individual points based on the part's geometry to create a collision-free toolpath.  MAX-PAC calculates an entire collision free zone and then determines the smoothest path through that zone to produce the best part in the shortest amount of time. This approach also enables MAX-PAC to machine parts other software can't. 

Other CAM systems use an approach that results in a "jerky" motion as seen here. Note how the tool flip-flops around the lead and trail edges:

MAX-PAC's approach results in a much smoother machine motion, especially as the tool goes around the lead and trail edges:

For example, we have a large OEM customer who was trying to machine an impeller. The software they were using at the time could not find a toolpath that would enable them to manufacture the part as designed. After months of trying, they approached Concepts NREC with their problem. We were able to deliver a workable toolpath the next day. Needless to say, the customer switched software! 

Software Highlights

With MAX-5, you can machine open impellers with a higher quality finish, faster!

advanced flank
advanced flank

Software Highlights

MAX-PAC Add-On Modules

MAX-PAC offers several different add-on modules that are focused on specific milling needs. You can purchase any combination of modules to meet your specific machining requirements.

MAX-PAC Add-On Modules

MAX-PAC offers several different add-on modules that are focused on specific milling needs. You can purchase any combination of modules to meet your specific machining requirements.
MAX-PAC_xl
MAX-5 –Flank Milling
MAX-AB_med
MAX-AB – Point Milling
MAX-SI_sm
MAX-SI - Integral Shroud Milling
MAX-SB_sm
MAX-SB – Single Blade Milling

Software Support

Benefits

 

3+2_MAX-PAC

 

  • Achieve faster roughing using 3-axis toolpaths at an arbitrary angle (3+2)

  • Provides consistent cutting conditions enabling greater feed rates as well as longer tool and machine life.

  • Helical entry provides smooth engagement of the cutter and eliminates the need for drilling

  • Save 5-axis machining time by performing roughing operations on 3-axis machines

  • Save programming time by calculating roughing toolpaths together with finish toolpaths in the same software package on the same geometry

  • Reduce software costs by eliminating the need for a separate package to calculate 3+2 roughing toolpaths

3plus2 roughing-777234-edited

3plus 2 roughing

 

Benefits

  • Achieve faster roughing using 3-axis toolpaths at an arbitrary angle (3+2)
  • Provides consistent cutting conditions enabling greater feed rates as well as longer tool and machine life.
  • Helical entry provides smooth engagement of the cutter and eliminates the need for drilling
  • Save 5-axis machining time by performing roughing operations on 3-axis machines
  • Save programming time by calculating roughing toolpaths together with finish toolpaths in the same software package on the same geometry
  • Reduce software costs by eliminating the need for a separate package to calculate 3+2 roughing toolpaths

MAX-PAC Add-On Modules

MAX-PAC offers several different add-on modules that are focused on specific milling needs. You can purchase any combination of modules to meet your specific machining requirements.

3+2 Roughing Brochure

3+2 Roughing enables turbomachinery roughing out of impellers using 3-axis algorithms, keeping a constant tool vector. This strategy optimizes the toolpath to provide constant cutting load, making it suitable for high-speed machining. This is extremely helpful for large (>0.5 m) diameter parts and/or hard materials where roughing using the traditional 5-axis strategies of MAX-PAC is less efficient.

3plus2 Roughing-1

Find Your Rep

North America

Mr. Don Roberson

Phone:

Email: DRoberson@conceptsnrec.com

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CAM Software Workshops

Find Your Rep

" Kinner Manufacturing was founded in 2007 with the goal to deliver the highest-quality bladed parts to our customers. To deliver on that goal, we needed the best CAM software available. As a machinist, I had worked with many CAM systems. I noticed that blades were always better when produced with Concepts NREC software, so we called them to set up a demo. Having never actually used the software to create a design, I was surprised at how intuitive it was. We decided to go with MAX-PAC™ and we were trained and creating programs right away.

As we grew, we noticed that a lot of our customers were creating their blade geometry using Concepts NREC’s CAE software. This makes for a seamless transition to the CAM software helping to ensure the original design intent. Having a suite of software that spans the whole process eliminates some of the issues that can happen when designs are switched between different programs.

Here at Kinner Manufacturing, we think that MAX-PAC is the best solution to the unique challenges of 5-axis machining of bladed components."

Ray Kinner,  Owner

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