Imagine a heavy steel billet undergoing precise five-axis machining, transforming into a high-precision connecting rod. This is not merely a reshaping of metal—it’s a fusion of technology and artistry. Sebastian Herr, Application Technology Director at Hurco, provides an in-depth look at how Hurco’s control system achieves this process with unmatched efficiency and accuracy.
Hurco’s Control System: Power Rivaling CAM Software
Hurco’s recently released video, "Connecting Rod Milling," demonstrates the complete process of manufacturing stainless steel connecting rods using five-axis machining. The case study proves that Hurco’s control system performs on par with CAM systems in trochoidal milling applications. The principle remains consistent: the tool executes a rotational motion upon entering the workpiece, gradually immersing itself until fully submerged, enabling milling along the entire tool length. Throughout the cycle, motion patterns adjust dynamically to maintain a consistent clamping center.
Trochoidal Milling: Seamless Integration of Technologies
The video highlights Hurco’s ability to integrate TopSolid’s trochoidal milling functions into conversational programming, achieving flawless synchronization with negligible deviations in simulation results. Tool setup and machine configurations remain identical, ensuring uninterrupted program execution. This exemplifies the synergy between Hurco’s foundational conversational programming and CAM systems, which generate DIN-ISO code for advanced applications.
Hurco emphasizes that NC programs are fully embedded within the control system’s conversational interface. The choice to use CAM systems is driven by their superior performance in handling complex contract manufacturing scenarios, where multiple machines and operators rely on limited CAM workstations. Hurco’s flexible control system allows programmers to integrate diverse program sources, while operators need only fundamental machining knowledge—unlike competing systems that demand extensive training and investment.
Automated Pallet Loading: Enhancing Efficiency
Beyond advanced controls, automation plays a pivotal role in productivity. Hurco offers a range of automation solutions, including in-house products and collaborations with partners like ROBOJOB and EROWA. The video features EROWA’s pallet-loading system, though Hurco remains open to custom automation concepts tailored to client needs.
The demonstration involves a 60 kg stainless steel block secured by LANG TECHNIK’s compact clamping modules (75 mm wide each). A 1 mm-deep, 125 mm-wide recess on the billet’s lower edge allows hydraulic mechanisms to anchor the workpiece with minimal clamping force yet maximum stability. This design dampens vibrations, enabling high-performance machining under consistent load conditions.
Simulation: Ensuring Precision Before Execution
Hurco’s control system includes robust simulation capabilities, allowing users to import 3D CAD models of raw castings and finished parts via the "Solid Model Import" option. At the 10-second mark in the video, the system overlays the machined part’s model onto the casting, simulating predefined operations to verify accuracy. From 39 seconds onward, the real-time simulation tracks metal removal rates and toolpaths, providing visibility into cutter depth and motion patterns.
Conclusion: A Turnkey Solution for High-Performance Machining
The connecting rod process exemplifies Hurco’s holistic approach: DIN/ISO subroutines integrate seamlessly with conversational programming, simulations run flawlessly, and challenging stainless-steel operations proceed smoothly. Adaptive milling strategies and vibration-damping clamps enable ultra-thin machining of connecting webs, which can be snapped off post-processing. Deburring completes the rod—all in a single operation and clamping cycle.
Collaborative Partners
-
Automation: EROWA
-
Tool Clamping Technology: LANG TECHNIK
-
CAD/CAM System: TOPSOLID
-
Distributor: MOLDTECH
Your message must be between 20-3,000 characters!
