TrueMill

TrueMill is a significant milestone step in the long history of machining. TrueMill is the name for a patented set of discoveries centered on controlling tool engagement while machining a part of almost any type or material. By controlling the tool's engagement with the material, TrueMill has repeatedly proven to greatly increase material removal rates (MRR), decrease cycle times and extend tool life. The research and discoveries that went into the development of TrueMill took place (and continue to occur) at the Camarillo, California-based CAM software company, Surfware, Inc.

TrueMill toolpaths are very different from other tool motion paths. All corners, all the sharp directional changes have been effectively eliminated. The tool never plows into a corner. The technology works on all part shapes. Rather than generating toolpaths based on a given stepover value and the shape of the geometry being machined, TrueMill manages tool-engagement angles to produce toolpaths that are far superior to anything on the market today. The net result is that much more aggressive cutting parameters can be used, resulting in dramatically reduced cycle times.

The core problem in milling has always been the inability to control the cutting tool's engagement with the material. This makes it physically impossible to keep the load on the tool constant and forces machines to be run at far less aggressive cutting parameters than they are capable of, resulting in longer cycle times. TrueMill solves this core problem. The motion of the toolpath is designed with consideration for the in-process material boundary everywhere along the toolpath to ensure that the tool is never over-engaged. The toolpath does not require adjustment because the tool will never be buried in the first place. The toolpath stays as close as possible to the desired engagement angle without ever exceeding it.

TrueMill toolpaths are engagement-angle driven, not geometry driven. In other words, the shape of the geometry doesn't dictate the flow of the toolpath. Rather, each cut is made such that the next cut can be made at the desired engagement angle. The part shape is ultimately produced, of course, but it doesn't really become apparent until the final passes of the tool. Because of this smooth, flowing, engagement-controlled motion, SURFCAM Velocity 4 Powered by TrueMill can be run at feedrates, spindle speeds, depths of cut and stepovers that might at first seem impossible.

The current approach to high-speed machining involves taking very light cuts. TrueMill enables the machine to run at high speeds with much heavier cuts. Also, due to the even loads, there is less stress on the machine and the cutting tool. Tool life is actually extended while cycle times are reduced. These two concepts used to be mutually exclusive.

Specialized toolpaths are usually the result of treating a symptom of the problem, rather than solving the problem itself. With TrueMill, the core problem that produced all of these symptoms in the first place has been solved. Since there are no symptoms to treat, there is no need for multiple, gimmicky toolpath options. There is just one strategy that works in all cases. It even removes the distinction between pocketing and contouring or profiling. You just select your geometry and TrueMill knows what to do.