Optimization software programs are an off-line attempt at generating optimized NC programs. They may succeed in reducing machining cycle times to a degree only in cases where blocks are being cut. However, optimization software cannot be used when machining castings or forgings because the software does not have geometric data on the varying depth of cut. In addition, as an off-line system, optimization software has no way of protecting tools from breakage in case of unexpected load increase. In contrast, through their on-line real-time response to spindle load, ACM systems take into account variations in actual cutting conditions - because this information is received in real-time during cutting. As a result, ACM systems can automatically adjust the feed rate and thus, cycle-times are always reduced to the absolute minimum. Furthermore, ACM systems monitor tool wear and protect tools from breakage – which off-line optimization software can never do.

In purely financial terms, ACM costs a small fraction of the additional price of a high-speed machine (HSM). Cycle time savings can be achieved on existing conventional machines by applying ACM systems in roughing and semi-finishing operations without the need to invest into HSM . Moreover, ACM systems have the added advantage of ensuring tool protection. The original purpose of HSM was finishing operations where a small amount of material is removed at a fairly constant depth and roughing operations on softer materials. When used in roughing harder materials, HSM machines suffer greatly from wear and tear and require a great deal of maintenance thus incurring machine downtime.

Adaptive options that are offered on some CNC machines require the manual input of the maximum permissible load/power value for each specific tool in order to protect the machine. They do not adjust the feed rate continuously up/down throughout the process as a function of actual load/power in a controlled manner. Therefore, these options cannot reduce cycle times and at best they protect the tool if load limits are set correctly for each tool.

Each machine needs a separate ACM system which gets configured for that specific machine.

Absolutely not. Metal cutting operations under ACM control do not need any intervention once setup parameters have been entered. Tool referencing commands inserted into NC programs take care of the tool changes and inform ACM in real-time of any new tool placed into the spindle.

As long as the basic setup has been carried out, the ACM system runs in the background. Operators simply run their NC programs in Automatic Mode. For the setup, basic tool and material types should be selected from the system’s built-in library for each part. Minor tool referencing commands need to be added to the NC part programs which inform the system of the specific tool selected.

No. ACM systems increase the feed only to its maximum permissible rate for the current tool. In addition, the system is equipped with an internal tool protection mechanism that safeguards tools on impact.

No. OMATIVE’s breakthrough ACM technology automatically calculates load limits for each tool. The system ensures adjustment of the feed in order to maintain the cutting conditions within these limits without any manual intervention.

ACM systems can make use of OMATIVE’s NC Program Editor which assists in inserting the required tool referencing commands into NC programs without affecting the part in any way.

Yes. In spite of the faster feeds that ACM systems generally apply prior to impact (during air cutting), they are equipped with very advanced protection algorithms to protect tools upon impact. Each tool type is protected on impact according to an algorithm specifically designed for that tool type. In addition to impact protection, ACM systems prevent damage also during material cutting.

Yes. As spindle loads increase due to a worn tool, ACM systems adjust the feed accordingly. Conversely, sharp tools are automatically run at faster feeds.

No limitation.

Using a special tool referencing mechanism that is set up at installation time, the system automatically receives information about a changed tool from the CNC as and when the tool is changed. All that is required is a couple of simple commands entered into the current NC program after each tool selection.

By default, ACM uses basic parameters for each tool and workpiece material from the CNC. ACM performs different optimization processes for each tool. These parameters are saved in the system’s database for each job. When a job is run again, ACM will recall all the tool and material parameters; so no setup is required again. Data may be entered directly into the ACM or, alternatively, OMATIVE-Pro may be used on an PC connected to the machine.

ACM systems begin their control of the cutting process immediately after rapid traverse just as G01 is activated. This is also true of the tool protection capabilities of the system.

ACM systems are designed to optimize mainly roughing and semi-finishing operations where considerable amounts of material are removed. In finishing operations, ACM systems may be set to protect tools from being damaged by extra lumps of metal left over on the surface during roughing.

The ACM system can be used with virtually any milling/drilling/turning/grinding tool with the exception of small tools and finishing tools that do not usually apply a significant load on the spindle.

ACM systems can be used during finishing operations. However, since the finishing feeds are used determined on the basis of special surface finish criteria, it is not desirable for ACM systems to increase the feed during finishing. In addition, finishing operations are often run at relatively fast rates. The ACM system may be used during finishing to protect tools from being damaged by extra lumps of metal left over on the surface during roughing.

Yes, there is an ACM solution for every CNC, no matter the make or model. Depending on the specific CNC, each ACM system may be all-software fully integrated into the CNC, or firmware built into an Add-On Hardware package. All-Software solutions are only available for later CNC models. For older CNC models, ACM hardware components may be utilized.
For a list of ACM configuration options, click here.

The installation and setup of an ACM system in its CNC-integrated software configuration requires 1-2 hours. The installation and setup of an ACM system in the add-on (hardware) configuration on single-spindle machines requires about four hours of machine down time. The installation is carried out by an OMATIVE authorized installer who thoroughly integrates the system into production - from start to finish.

The ACM system operates only for those tools that have been pre-programmed. If necessary, the system can be disengaged from the machine at any time during cutting at the push of a special button.