Programming progress - CADCAM in action and latest developments

SPX Cooling Technologies uses Radan software (0844 800 1248) – part of the Planit Group – to process 90% of the 300 separate components that make up its larger 6 by 4 m cooling towers and the 100 components for the smaller towers. SPX is a leading full-line, full-service cooling tower and air-cooled condenser manufacturer and boasts more than 250 global patents in the power generation, industrial refrigeration and HVAC markets. The company's Worcester-based production operation manufactures parts up to 3 mm thick on its Trumpf 200 punch press, while outsourcing parts above 3 mm, sending them out to laser profilers. The company uses Radan to manage this and to program the in-house Trumpf machine, with Radan acting on bill of materials information to do so. Changes to their bespoke CNC software were needed when the company's American parent introduced a new SAP MRP system. SPX Cooling Technologies UK's CADCAM production scheduler, Karen Weaver, says that before the change the company used a bespoke Radan macro to expedite the process of data transfer from SPX's own MRP system to the Radan nester. One of the impacts of the change meant that the UK would access data from the USA's SAP MRP system, but the content of the data and structure of the files from the USA is completely different, rendering the macro unusable. Planit's Professional Services team was called in to investigate how the UK could utilise data from the USA's SAP system, while also being able to handle additional processes. Following a full appraisal, the Professional Services team devised a new specialised macro, based around SPX's requirements (see box item). MUCH TIME SAVED "This macro saves me so much time. It means we can meet customers' orders much quicker than we could without it," says Karen Weaver. "On average, it has reduced time by approximately 50% on programming each job, leaving me to concentrate on sheet steel utilisation and looking for other areas to further improve processes. "The consultancy time included Planit's Professional Services team setting up live weblinks, so we could run through the processes to ensure the macro would do exactly what we required. "It's an absolutely vital tool that automatically does everything we need. It operates through the user interface that was written specially for us, browses for the download file that we need, loads it straight into our system, and starts the process." Image: Planit came to the rescue of Karen Weaver, providing the automation she required Karen Weaver says that working with the information coming in from the USA, the new macro also does a lot more for them than the previous macro and does it a lot faster. "It creates our label identification – it feeds it to a Zebra printer on the shopfloor, so for every nest we produce the file is just dragged into 'print', and it prints off all the parts that are on that sheet. It also checks stock and creates a material upload spreadsheet in much more depth. The new macro also handles other processes, such as shopfloor documents, so the operators know exactly which tower they're building, how many programs they've got for that tower and how many towers are needed for a particular contract. "The macro's return on investment? In my opinion, it paid for itself in the first two months by simplifying our processes even further and making us even more efficient," Ms Weaver concludes. Radan may also be applied to manage/program SPX's press brakes in future, the company says. INTELLIGENT MACHINING Dixon Surgical is using SolidCAM (01226 241744) – including its revolutionary iMachining module, fully integrated inside SolidWorks, allowing it to generate just one machining program and use the CAD system's parametric tables to produce the other variants. Managing director Jay Dixon says: "A Ring Fixator instrument we make comes in 12 different sizes and, with other CAM systems, we would have had to create a separate model for each variation. SolidCAM really extends the reach of the CAD system. It enables us to design and manufacture the jigs and produce the CNC program for each of the three operations required to machine each Fixator from one CAD model and one CAM program, compounding time saving on top of time saving. Image: Time savings with iMachining have been incredible "It really impressed our machinists when they realised the amount of duplication of effort they had avoided!" The company already had SolidWorks from Cadtek Systems (01663 741405), but was prompted to look for a suitable CAM system, as he explains: "We have been using CNC machining since the early '90s. Programming was either manual or via on-machine conversational. Now we have standardised on Mazak machines, including a Quick Turn Nexus 200 MSY, which has milling, Y-axis and sub spindle, together with a VCN 410A vertical machining centre. "During 2010, we started to get requests for parts which were difficult to program on the machine, especially the mill-turn, and which were already modelled in 3D, so we started to look for a suitable CAM system." So, when the company went looking for that system, it had two main criteria: seamless integration in SolidWorks and the ability to program the company's Mazak Quick Turn Nexus. This eliminated every system, except SolidCAM, Mr Dixon offers. Following demonstration, he realised the new SolidCAM iMachining module could make a big difference to the ease of machining on the firm's Mazak Quick Turn Nexus, as it solved the problems of rigidity and efficient metal removal for milling operations on the machine. "For C-axis milling, you often have to compromise on the tooling you select, using longer projections than are ideal. Furthermore, mill-turn machines are not as rigid as a machining centre, have less power and the workholding is more flexible, with longer overhang situations than one would like. "SolidCAM iMachining has produced some incredible results on stainless steel; machining times are half of what we expected and the cutters last about five times longer than they did previously. We were used to getting unpleasant noises from the machine as it was cutting, but now we just get a sweet milling sound." A stainless steel spinal implant instrument, which Dixons Surgical manufactures on its Quick Turn Nexus, has a turned outside profile with milled sides and a through-pocket in the centre 26mm deep, both of which need to be cut using driven tools. The central pocket is cut with an 8 mm long-series carbide tool and finished with a 6 mm tool. iMachining enables this pocket to be cut in one pass at full depth, starting from a pilot hole, without vibration. "With traditional methods, we would have had lots of steps down the machined walls. With iMachining, we get a lovely smooth and flat finish," Mr Dixon confirms. Programming in SolidCAM is also easier. Dixons Surgical employs skilled engineers, so machinists are able to prepare their own programs, while the machines are cutting. Says the managing director: "With on-machine programming of complex parts, we would often have the machine tool idle for one or two days while the CNC program was being perfected. With iMachining, it just produces code which works first time, hugely increasing productivity by giving us more machining capacity and virtually eliminating programming and setting time. We feel our future is in producing complex orthopaedic instruments. We already have the experience, skill and knowledge required to finish surgical instruments to the required standard. Our investment in SolidCAM and iMachining is a crucial part of our expansion plans. We have been blown away by its performance." Moving to the US and Milwaukee-based Triangle Tool Corp has strategically positioned itself as a leader in moulds for large plastic parts. It has exclusively used Delcam's PowerSHAPE CAD system and PowerMILL CAM software (0121 766 5544), so when the company added large part machining to its repertoire, the company once again put Delcam to the test, with positive results. TESTED AND TRUE "When we started our specialty-machining division, we didn't know if we needed additional CAM capabilities," engineering manager Mark Pitzen explains. "Delcam told us to put the software to the test and the systems have excelled in all areas of machining of castings, forgings and other components." Triangle Tool is a 130-employee company in Milwaukee that produces moulds of all types for many of the country's most recognised names in home appliances, agriculture, consumer products and returnable packaging. It also manufactures custom components, castings and forgings for the aerospace, energy and transportation industries. "Because we have specialised in large products, it is common for steel blocks or forgings to weigh greater than 25 tons and need multiple, precision operations for each piece," explains Daniel Gouge, Triangle Tool's technical sales engineer. "Most companies would find this type of work intimidating, but Triangle Tool has specialised in large parts to become one of Wisconsin's strongest businesses. Not many companies have the capability to handle twenty such pieces at once, but this is commonplace for us." Using PowerMILL and PowerSHAPE has played a vital role in the company's new specialty-machining niche. "We have used Delcam software for years, because of the company's commitment to innovation and to the optimisation of the machining process," explains Mr Pitzen. "Every mould, forging or casting that Triangle Tool machines is fully programmed, paths verified and machined using Delcam products. "For our specialty-machining business, we use Delcam to program all of the intricate shapes and details. The versatility for both sides of our business has been instrumental in us being competitive and winning work. "Delcam has perfected its product to the point where there isn't anything we can't machine with efficient cutter paths," he notes. "Because it is so capable, we don't have the additional costs of having other CAM systems in-house. The learning curve is minimal with the software. Many shops won't make the investment in do-it-all software, but we did and Delcam makes programming and machining very cost effective." Image: Large mould tools and subcontract maching - both are satisfied with PowerMILL Box item SPX requirements for SAP integration [] Automation of Radan schedule loading from SAP BOM file, incorporating validation of 'live' Radan parts; [] Creation of 'Missing Parts' data file and pseudo Radan part files, created with associated BOM material attributes attached; [] Outsourced laser cut data requirements created, including spreadsheet and zipped DXF files, or native Radan files; [] Internal tracking data created (Win Shuttle lists); [] Shopfloor documentation for the punch and press brake operators; [] Material usage/order requirements spreadsheet created with options to; [] Order against existing stock levels; [] Order all material used; [] Nest part labels prepared for Zebra label printer situated on the shopfloor.