WFL is using its decades of experience to offer well-engineered software solutions relating to the manufacturing process with a MILLTURN complete machining centre. We will begin our new software solutions series by looking at WFL cycles. The technology cycles of WFL cover a broad range of standard and special technologies for all kinds of applications. These program modules make it possible to carry out efficient programming directly on the machine control or on a PC. Programs can therefore be created for both complex and simple workpieces in only a short period of time.

Turning, drilling & milling

The technology cycles from WFL simplify programming considerably and are a direct route to achieving the desired production result. The wide range of technology solutions fulfils all machining requirements. The technology cycles are diverse, for example thread turning, grooves, thread undercuts, drilling with chip breaking, deep hole drilling, gun drilling, turn-, face or path milling and much more.

Metal cutting & feed out

Cycle packages for crankshaft machining, for complex multi-axis machining with actuating tools or for a workpiece finish using grinding clearly show that a needs-based cycle configuration allows sector-specific requirements to be handled quickly and efficiently. There are many cycles to choose from, including Utronix (the virtual U-axis), Cranx-Basic (basic crankshaft package), Cranx-Advanced (extended crankshaft package), Cranx-Plus (complete crankshaft package), or also a 5-axis machining package and turning with swivelling B-axis, as well as deburring by means of 3-axis interpolation (centric holes) and cam milling. 

Gear cutting

From filigree internal gears with high accuracy requirements to large external gears that require high roughing efficiency – WFL offers the appropriate technological solution for every type of gear cutting.

Example cycle selections

• Flanx-Hob: Gear hobbing of external gears
• Flanx-Spline: Shaping of external and internal gears
• Flanx-Plus: Flanx-Hob and Flanx-Spline as a cycle package
• Flanx-LM: Milling of large gears with standard milling tools
• Flanx-Invo: Milling of external gears

Measuring

High-precision radio transmission probes, linear direct measuring systems and backlash-free anti-friction guideways transform the MILLTURN into a 3D measuring machine. WFL provides the user with comprehensive modular measuring software and proven expertise for intelligent measuring strategies, which serve to exclude as many error-causing variables as possible, right from the very start. There are several cycles to choose from here too: the standard measurement cycle package and the extended measuring cycle package, which contains the ultrasonic wall thickness measurement.

The ultrasonic measuring unit enables measurement of the wall thickness of components. Ultrasonic measurement is used for long pipes or deep internal contours that cannot usually be measured using a radio transmission probe. The WFL measuring cycles allow wall thicknesses to easily be measured and analysed. For example, the different analysis algorithms can be used to determine the centring error.

There are also cycles for recording measurement data and scanning.

Tool control & management

Turning, drilling and milling tools can be measured using the tool control cycles.

Cycle selection:

• Calibrating the tool probe
• Measuring the tool automatically
• Measuring the cutting radius
• Measuring the tool manually

All information relating to the existing tools is organised in a uniform manner thanks to the tool management software solutions. This makes it possible to achieve a considerable reduction in the set-up time and minimise tool costs, as the tools are always used until the end of their life.

Process optimisation

Intelligent software solutions for increasing efficiency ensure a reliable blank machining process with variable allowance without overloading machines and tools and without user interventions.

Cycle selection

• Adaptive control (for feed rate and spindle speed)
• Torque and speed restriction of the milling spindle
• Automatic geometric check
• Process time recording
• Coolant unit control with pressure control and flow monitoring

Process safety

The safety of the workpiece, tool and machine is a central objective in every machining process. Separate registration of all cutting force components in process monitoring ensures reliable detection of tool breakage, for example. The emergency retraction routines minimise the risk of rejection in the event of power outage.

Example software solutions

• Drive-independent emergency retraction routines, level 1
• Drive-independent emergency retraction routines, level 2
• Control-led emergency retraction routines
• iControl Basic+
• iControl Advanced+
• Automatic display of input screens

The benefits of the WFL software solutions

• Perfectly attuned to the MILLTURN software of WFL (Millturn PRO, CrashGuard Studio and CrashGuard)
• Comfortable programming on the PC and on the machine control
• Extensive range of standard and special technologies
• Considerable reduction in programming effort with WFL technology cycles
• Well-engineered solutions for process optimisation and maximisation of process safety
• Considerable reduction in tool costs thanks to advanced tool management
• Future-ready due to the best connectivity

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