Page 427 - Gear Technology Solutions

Roll optimization has to be turned on. It generates one complete flank as
shown in Figure 3, as opposed to toggling in each roll position from the first to
the second flank (used for cutting completing parts with endmills).

Also flank optimization has to be turned on. It arranges the process to stay
for example in the lower position and machine all lower flanks. After all the
lower flanks are finished, the tool moves in the upper position and finishes all
upper slots.

The lowest number of roll positions recommended is 10. A good surface fin-
ish is achieved between 14 and 30 roll positions. More roll positions require
proportionally more machining time. A higher number of swing positions have
no influence onto the machining time.

If the number of swing positions is too low, polygonal facets in face width
direction become visible. If the number is too high, then the part program is
becoming larger, but the machining time remains the same.

Figure 6: Process and geometry input screen

In soft cutting, a plunge, without any swing motion can be used to remove 70%
of the slot material in a very short time. It is recommended to set the plunge
depth factor (Figure 6) to 0.900000, which leaves the generating roll process
some material to clean out the root bottom.

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