1. M.A.L. Products HIGH PERFROMANCE MACHINING TECHNOLOGY from
MAL Manufacturing Automation Laboratories Inc
Vancouver, B.C., CANADA
M.A.L. Products

2. MAL Inc. has two lines of Products to boost productivity of machining operations
ShopPro – Practical, easy to learn and use, integrated tap testing, chatter avoidance and diagnostics software for milling
CUTPRO – Advanced Simulation and Testing Software tool box to design, optimize, measure and diagnose machining operations, cutters and machine tools.
Products

3. ShopPro/CUTPRO Instrumentation Set
Labtop computer
National Instruments NI9233 USB Measurement Box
Impact hammer and accelerometer
Microphone
Instrumentation

4. 3 Simple Steps in Using ShopPro
Enter material type and basic cutter geometry
Tap test the cutter on the machine or define dynamic parameters
Chatter stability lobes (vibration free speeds and depth of cuts), torque, power and material removal rates will be displayed instantly.
The noise from the machine can be recorded, and ShopPro provides automated diagnosis and advice.
ShopPro Steps

5. ShopPro Step 2 - Tap Test the tool to obtain machine stiffness

6. Step 3- Machine Sweet Spots (depth of cut, spindle speed) are displayed with Torque, Power and MRR
ShopPro

7. CUTPRO Machining Software Modules
MALTF – Advanced Tap Testing System
MALDAQ – Multi Channel Data Collection
MODAL – Modal Analysis with machine data base and tool tuning modules
MILLING – Advanced cutter design, optimization and simulation system for milling
TURNING, DRILLING and BORING Modules
SpindlePro – Finite Element Modeling and Analysis of Spindle Drives
Virtual CNC – A complete 5 axis modular CNC system design with drive design, sensors, amplifiers, friction, trajectory generation, interpolation and control modules
CUTPRO Modules

8. CUTPRO :Parametric Tool Definition in APT

9. Helical flute is wrapped around the solid end mill.

10. CUTPRO: Prediction of milling forces from tool geometry and orthogonal cutting material data.

11. CUTPRO: Tapered Helical Ball End Milling (Jet Engine Machining)
Cutter:Taper helical ball end mill, rake angle=10°, relief angle=10°, D=6.0,
R=3.0, Rr =0, Rz =3.0, h=38.0, lead=105.0mm, a=0°, b=4.0°, Nf =1
Cutting Mode: Slot cutting
Cutting Coefficients: Orthogonal cutting coefficients for Ti6Al4V
by using orthogonal to oblique transformation
CUTPRO can predict the cutting forces on the tool/machine accurately for a given tool geometry and material.
CUTPRO: Tapered Helical Ball End Milling (Jet Engine Machining)

12. CUTPRO: Inserted Helical End Mill

13. CUTPRO: Prediction of Serrated Cutter Forces

14. Source of Vibrations in Machine Tools
Low speed heavy machining usually excites the spindle housing, column and fixture. High speed machining always excite the spindle, tool holder and tool since they have higher natural frequency and flexibility.
Source of Vibrations in Machine Tools
FlexSource.ai

15. CUTPRO : Vibration Model of Milling System
The mechanism of chatter in milling is shown here. The chip thickness oscillates, so as the forces and vibrations.
CUTPRO : Vibration Model of Milling System

16. REGENERATION MECHANISM

17. Process simulation and chatter stability lobe prediction in CUTPRO
TF measurement
MALTF
FRF file
Milling Module
Modal Analysis Module
Stability Lobes
CMP
files
UBC developed the first advanced milling process simulation and chatter avoidance technology, and its application is shown here.
Process simulation and chatter stability lobe prediction in CUTPRO

18. n=15400 [rpm], DOC=4.0 [mm]
N=17000 [rpm], DOC=4.5 [mm]
2884 [Hz]
Chatter frequency
567 [Hz]
Tooth passing
frequency
Milling Mode: Slotting
Machine tool: Mori Seiki SH403
Tool:Jabro,16.0 [mm], 2-fluted cylindrical endmill
Feed rate: 0.1 [mm/tooth]
Surface finish
Surface finish
Increase the material removal rate by 500% and avoid poor surface finish and tool/spindle damage

19. Slot milling of Al7050 with 2 Fluted, 16mm diameter end mill.
N=17,000 [rev/min],
depth of cut = 4.5 [mm]
NO CHATTER
N=15,400 [rev/min],
depth of cut = 4.0 [mm]
CHATTER
Slot milling of Al7050 with 2 Fluted, 16mm diameter end mill.

20. ShopPro: Detection of Chatter with a
microphone

21. Chatter is avoided by selecting proper speed recommended by ShopPro

22. High Speed Milling of Spiral
Material: AL 7050-T7451, 100x100x50 [mm]
Tool: Jabro 16 [mm] diameter, 50 [mm] length Number of flutes:2
Roughing [rpm] Depth of cut: 7mm slotting Chip load: 0.2 mm
Finishing: 20,000 [rpm] Depth of cut: 1mm, Width of cut:10 mm, Chip load:0.25 mm
Thickness of the wall: 0.15 [mm] Height of the wall: 35 [mm]
Feed rate: 0.25 [mm/tooth] Machine tool: Mori Seiki SH403
Cycle time:9 min 20 sec.
High Speed Milling of Spiral

23. Impeller Milling UBC + P&WC NSERC Chair
Cycle Time Reduction: 62%
Cycle Time Reduction: 62%
BEFORE
AFTER
Surface roughness improved by 8.4 fold
Impeller Milling UBC + P&WC NSERC Chair

24. Example - 2 Force in X and Y directions Surface finish 4.5 [mm] 17600
10600
17600
4.5 [mm]
Force in X and Y directions
Surface finish
If the cutting condition is selected incorrectly, chatter may destroy the tool, holder and spindle bearings.
Example - 2

25. Types of cutters in CUTPRO
Milling Module
Types of cutters in CUTPRO

26. Customers and/or Research Partners
+ Universities and many more…
Customers and/or Research Partners