The efficiency of milling processes is a crucial topic in production as any deficits in process planning scale with the number of produced parts. While a lot of effort is put in improving quality and efficiency of the last finishing step, time-consuming roughing operations often lack efficiency. The potential for scalable improvement in this area is quite high but often lies idle. AixPath developed together with Boeing a High-Speed Adaptive Roughing (HSAR) CAM module as a plugin for Siemens NX, which implements a

unique algorithm for calculation of toolpaths for high productivity rouging milling. These toolpaths are designed to control engagement conditions between cutting tool and material in all situations of different geometric variations. The ability of the algorithm to control tool engagement against predefined conditions makes the calculation of toolpaths for highly productive methods of material removal possible. HSAR is fully integrated into the industry standard PLM software, Siemens NX and provides the capability to calculate high speed toolpaths for roughing milling of prismatic shaped parts using either the solid geometry designed in NX or their wireframe edges. HSAR module also integrates machining stability data to select most productive chatter free cutting conditions for a given combination of milling tool and machine tool. With the provided functionalities of the CAM module roughing operations while machining Titanium can be reduced by up to 40% and for Aluminum up to 30%.