Tell Tool of Westfield, Mass., has integrated Vericut CNC simulation software into its NC-program prove-out process. It ensures every part is accurate, dimensionally correct, and efficient when they hit the shop floor. As a result, the company reduces manual prove-out processes by as much as 80% and practices lights-out machining on some of its first-time parts to improve efficiency, productivity, and profitability.

Besides electronic engine controls, auxiliary power units, and other systems, Tell Tool manufactures fuel-control units using Vericut’s model export capability integrated into the manufacturing process. When customers contract Tell Tool for a fuel-control unit, there is often no design model of the final part shape. What Tell Tool gets are specifications for the dimensions of the inside of the part, minimum wall thicknesses, specific structure requirements, and other information.

To create the outer shape of the control unit, Tell Tool reverse engineers the unit from the inside out using internal-part specifications such as fuel-control-housing dimensions and the minimum wrap-stock requirements around each feature. Within a CAD/CAM system, it creates cutter paths around the minimum wrap-stock requirements, which run in Vericut to create the in-process part shape.

Vericut exports the in-process shape as an in-process file that converts to an STL file, which serves as a starting point for programming the next operation in the CAD/CAM system. After the part is programmed and run through Vericut, there is an in-process model of the fuel-control housing’s shape. This finished shape, which can convert to an STL file, goes back to the customer.

Prior to implementing Vericut, programmers approximated as to the shape of the in-process material and ran the cutter path within those imaginary boundaries. As a result, there were a lot of air cuts where the cutter did not contact material.

For companies like Tell Tool, the latest release of Vericut, version 5.4, also improves documentation processes. Such software contains the critical manufacturing information, especially a representation of the in-process geometry, necessary to accurately document a process. One example is creating inspection instructions. Vericut 5.4 automatically creates inspection instructions complete with in-process feature dimensions, which are generated during NC-program simulation. Most shops manually create inspection instructions. However, without an electronic in-process model of the part, there is a limited knowledge of the in-process state of material. Thus, manual methods require a certain degree of technical expertise and are prone to error.

Outdated secondary-operation machines were strangling the productivity of a Chicago-area screw machine shop’s impressive battery of CNC screw machines. Now, CNC drilling and tapping machines and turning centers are providing secondary machining efficiency that has raised the firm’s performance to a level few competitors can match.

When you drive past the building, with its concave front and narrow, close-set, floor-to-ceiling windows, you would guess an insurance firm, or an engineering or architectural firm, or perhaps an association office. In fact, the distinctive exterior pictured in Figure 1 houses the operations of General Automation, Inc., one of the most impressive screw machine shops in the country.

General Automation specializes in, among other things, Swiss screw machine parts, that is, workpieces with high length-to-diameter ratios. The firm produces them on numerous Swiss-type cam automatic screw machines, arranged like spokes on large wheels, bar feeds toward the center. (The arrangement makes the most efficient use of floor space and makes it easier for the operators to load the machines and tend their operation.)

Although cam-operated screw machines have been around for generations, they remain a very competitive method for producing workpieces in large quantities. They can produce workpieces in less time (a shorter cycle) than by most other methods.

But cam automatics are inefficient when the job involves making a few prototypes, or a small quantity of workpieces, or when machined part dimensions must be accurate to one or two ten-thousandths of an inch. Such jobs are best handled on CNC screw machines.

Advantages Of CNC

Screw machine shops are aware of the advantages of CNC screw machines; many have one or two in order to remain competitive on prototype work, short run jobs, and jobs where fast turnaround and/or high quality are critical. However, few shops are in a position to invest in enough CNC screw machines to comprise a separate department.

General Automation is one of the few. The firm operates some 63 Nomura CNC Swiss-type screw machines–the largest concentration of such machines in the U.S. The CNC Swiss-type screw machine offers a number of advantages over the older cam automatic screw machine. As its name implies, the cam automatic’s cutting tool movements are controlled by a set of cams specially made for the workpiece being produced.

The CNC screw machine needs no cams. Tool movements are automatically determined by data from the dimensions of the part, fed into the machine’s CNC unit. The workpiece can be programmed on the CNC right at the machine. Or, as is more often the case, the program can be prepared on a programming system located off the shop floor, and loaded in the machine’s control when required. The control’s “memory” is capable of storing dozens of workpiece programs; preparing the CNC screw machine to produce a different workpiece simply involves calling up the program for the next job, minimizing machine downtime between jobs.

Because CNC machine tools handle job change-overs much faster than manual or automatic machines, they are usually thought of as “short-run machines.” By contrast, cam automatics, which are noted for their very rapid cycle times, are considered “production machines,” ideal for producing large quantities of workpieces over long periods of time.

http://cnc-info.blogspot.com/Outdated secondary-operation machines were strangling the productivity of a Chicago-area screw machine shop’s impressive battery of CNC screw machines. Now, CNC drilling and tapping machines and turning centers are providing secondary machining efficiency that has raised the firm’s performance to a level few competitors can match.

When you drive past the building, with its concave front and narrow, close-set, floor-to-ceiling windows, you would guess an insurance firm, or an engineering or architectural firm, or perhaps an association office. In fact, the distinctive exterior pictured in Figure 1 houses the operations of General Automation, Inc., one of the most impressive screw machine shops in the country.

General Automation specializes in, among other things, Swiss screw machine parts, that is, workpieces with high length-to-diameter ratios. The firm produces them on numerous Swiss-type cam automatic screw machines, arranged like spokes on large wheels, bar feeds toward the center. (The arrangement makes the most efficient use of floor space and makes it easier for the operators to load the machines and tend their operation.)

Although cam-operated screw machines have been around for generations, they remain a very competitive method for producing workpieces in large quantities. They can produce workpieces in less time (a shorter cycle) than by most other methods.

But cam automatics are inefficient when the job involves making a few prototypes, or a small quantity of workpieces, or when machined part dimensions must be accurate to one or two ten-thousandths of an inch. Such jobs are best handled on CNC screw machines.

Advantages Of CNC

Screw machine shops are aware of the advantages of CNC screw machines; many have one or two in order to remain competitive on prototype work, short run jobs, and jobs where fast turnaround and/or high quality are critical. However, few shops are in a position to invest in enough CNC screw machines to comprise a separate department.

General Automation is one of the few. The firm operates some 63 Nomura CNC Swiss-type screw machines–the largest concentration of such machines in the U.S. The CNC Swiss-type screw machine offers a number of advantages over the older cam automatic screw machine. As its name implies, the cam automatic’s cutting tool movements are controlled by a set of cams specially made for the workpiece being produced.

The CNC screw machine needs no cams. Tool movements are automatically determined by data from the dimensions of the part, fed into the machine’s CNC unit. The workpiece can be programmed on the CNC right at the machine. Or, as is more often the case, the program can be prepared on a programming system located off the shop floor, and loaded in the machine’s control when required. The control’s “memory” is capable of storing dozens of workpiece programs; preparing the CNC screw machine to produce a different workpiece simply involves calling up the program for the next job, minimizing machine downtime between jobs.

Because CNC machine tools handle job change-overs much faster than manual or automatic machines, they are usually thought of as “short-run machines.” By contrast, cam automatics, which are noted for their very rapid cycle times, are considered “production machines,” ideal for producing large quantities of workpieces over long periods of time.

http://cnc-info.blogspot.com/

Working in all materials, particularly high-grade stainless steel and aluminium, and in small volumes of often only one-off up to 100, Marcus Allum has steadily invested in CNC to satisfy customers’ demanding turn-round times. Visitors to Allum Precision Engineering’s rural site in Berkshire are easily lulled into a false impression of the company as they travel down a dirt track, with open fields on either side and towards a series of traditional farm buildings. From the outside, there is no indication that the ageing stable block is home to a high-tech machining centre and other CNC machines that are proving key in the supply of precision components to a wide range of local manufacturers.
Even since Marcus Allum formed the company in the mid-’90s, when the initial manual machines - a lathe and a turret mill - were being operated from a trailer while awaiting planning permission to use the outbuildings for light industrial use, he has continually strived to at least remain on par with his competitors, but preferably one step ahead.

This he has succeeded in doing through combining clever and innovative engineering with regular investment in CNC machining - the latest of which is a Gate Challenger VMC-610 vertical machining centre, fitted with Anilam CNC, from Gate Machinery International.

His current order book includes a wide range of precision-engineered parts for the automotive sector (ie, exhaust fittings), telecommunications (mobile ‘phone components), aircraft (microlite wing struts) and oilfield and chemical industries (vacuum compressor heads) as well as a plethora of ‘hobby’ jobs such as the refurbishment and replacement of locks and keys for churches.
Working in all materials, particularly high-grade stainless steel and aluminium, and invariably in small volumes of often only one-off (prototype work) and batches of no more than 100, Marcus Allum has steadily invested in CNC to not only utilise the machines’ higher speeds and feeds, to satisfy customers’ demanding turn-round times and the required consistent quality of often complex components, but also to overcome a problem that is familiar to many companies - lack of skills.

‘Although I have the services of two or three skilled operators on a part-time basis, the use of CNC milling and turning has largely enabled me to solve this perennial problem,’ he says.

http://cnc-info.blogspot.com

Featuring Windows-based environment, PMAC NC v5.0 can be combined with user’s favorite PC-compatible CAD/CAM or conversational package. Multi-tasking utilities of Windows operating system enable CNC parts to be run while user simultaneously programs other applications. Connectivity options, such as Ethernet and USB2.0, help reduce time spent transferring part program files. Part program size is limited only by hard drive space.

Customizable Windows GUI for PC Based CNC control
CHATSWORTH, CA- August 20, 2004- Delta Tau Data Systems Inc., the technology leader in multi-axis programmable motion control solutions, today announced the release of PMAC NC 5.0 software, a Windows-based customizable GUI for PC based CNC control.
“With the combination of PMAC HMI and the NC server, this new release offers the most advanced and flexible CNC software package available,” said Vince Burokas, Product Manager for CNC at Delta Tau Data Systems, Inc. “This new version builds on Delta Tau’s previous G-code software package that leverages Delta Tau’s legendary servo hardware performance to bring unprecedented levels of block throughput speed, cutting accuracy and the flexibility of a PC-based environment to the shop floor.”

NC 5.0 has all of the features of the previous version with the added advantage of easy user screen customization. The Windows-based environment allows users to combine NC 5.0 with their favorite PC compatible CAD/CAM or conversational package. This gives the operator or programmer the flexibility to program directly at the machine or remotely at a desk. The multi-tasking utilities of the Windows operating system enable CNC parts to be run, while the user simultaneously programs other programs. Connectivity tools, such as Ethernet and USB2.0, are easy to set up and provide unparalleled reductions in time spent transferring part program files. The part program size is limited only by the hard drive space.
The combined CNC software and one Advantage 410 hardware package from Delta Tau can deliver block throughput speed of more than 1,000 blocks per second. Segmented block look-ahead is available, virtually eliminating overshooting and undercutting. This allows the programmer to concentrate on part geometry and not control capabilities.

http://cnc-info.blogspot.com/

Turning and machining centers can now use FlexLink Ethernet connectivity from Hitachi Seiki (Itasca, IL) for its line of Seicos Sigma controls. It features software and a Universal User Port (UUP) Ethernet connection that provides bidirectional communication between the CNC machine and an external PC device or PC network.

The new design uses a standard RJ45 Ethernet connection so customers have options as to the external PC device that can be connected to the machine. Linking to a local-office PC network is the most likely application. However, it is possible to use Hitachi Seiki FlexLink technology to connect with a hand-held personal digital assistant (PDA) or a laptop computer or for use over the Internet for remote monitoring and management.

The open CNC architecture is said to be more reliable than competing designs because proven CNC controls manage the machines, while the open architecture provides real-time management information about the machine and its production. This avoids instability that might be inherent in PC-fused linkages or links dependent upon PC operating systems.

Before production, Seiki FlexLink technology provides job scheduling and production control. It can access tooling and Fixturing databases, verify CAD/CAM, or order required tools. Interactive connectivity can also provide for remote auto tuning for high-speed machining.

During production, the system provides remote diagnostics and operation. Real-time monitoring of position, programs, and displays is possible from any terminal. Event calls can be made by e-mail, and SPC data can be efficiently gathered, while remote monitoring at the management and supervisory level is available.

The system provides data for productivity analysis along with a permanent record of all machine data before, during, and after the job.

Perhaps you have been given the job of selecting and purchasing a coordinate measuring machine (CMM) or some other geometric measurement system. Now you are comparing the various brands of equipment and trying to figure out what differentiates them, with software being a secondary consideration. If that is what you are doing, I am going to suggest that you may have the cart before the horse and would do well to reorder the decision-making process.

Consider evaluating the software first and then selecting equipment based on whether or not it is compatible with the software. Of course, the equipment must be suitable to the application. This drives everything. However, considering software first will help focus on the big picture—enterprise goals of inspection and how they can be realized more intelligently, with the highest quality results, the least effort and the lowest costs.

The idea of making measurement processes more software-centric is a core tenet of computer-aided inspection (CAI). This decade-old concept was advanced primarily within the R&D and high-tech manufacturing communities primarily because it required expensive custom measurement and analysis software to tie inspection results back to the computer-aided design (CAD) system.

Today that is changing as software developers introduce a range of off-the-shelf metrology packages with enormous amounts of built-in intelligence. These are capable of both maximizing the performance and operation of specific devices and providing a bi-directional conduit for metrology information between and amongst diverse measurement devices and CAD databases. The result is an enterprise metrology system capable of realizing the goals of inspection at speeds and efficiencies well beyond anything currently available.

Think of this new breed of measuring device software as an intelligent inspection system. As such, it is an extension of the original CAI model in that it eliminates many of the fundamental process inefficiencies associated with the traditional inspection process. Call the extended model CAIIS (pronounced case) for Computer Aided Intelligent Inspection System. This acronym provides an accurate and helpful description of the versatile inspection software tools that are becoming available from many measurement system manufacturers and third-party software providers.

CAIIS Missions
portable measurement systems, A range of portable measurement systems, such as the laser tracker and measuring arm, can be programmed and operated using common CAIIS software based on the PC-DMIS CMM engine. Source: Wilcox Associates

When evaluating CAIIS alternatives, it is important to keep in mind the ultimate missions of the inspection processes—transforming raw data collected by the measurement devices into actionable information to:

* Allow customers to buy off on the manufactured goods, so the enterprise can ship them, send an invoice and make a profit.
* Monitor and adjust manufacturing processes to maximize equipment uptime while eliminating scrap and rework.
* Troubleshoot design and manufacturing problems to improve product performance, reduce recalls and warranty issues and get to market faster to gain a competitive advantage.

Note that this way of thinking about inspection intelligence gets immediately into the core issues of the measurement system’s bottom-line impact. It also helps to avoid being overly distracted by technical details, which may be important to the selection process but secondary to accomplishing these objectives better, faster and with less associated cost. Off-the-shelf CAIIS packages do this because they view the goals of inspection from the enterprise solutions level, and, as such, target the bottlenecks in all aspects of the inspection process.

Primacy of CAD

Today, more and more of the work of manufacturing happens in virtual reality. Manufacturers design, model and refine products, parts and assemblies within their CAD systems. Then, using the information embedded in the CAD model, computer-aided manufacturing (CAM) systems create the tool paths for manufacturing parts with a minimal number of setups and least possible movement of parts among computer numeric control (CNC) equipment. In the virtual world, to the greatest extent possible, data is moved instead of parts, and that drives out substantial labor cost.

CAIIS is a logical extension of the CAD/CAM progression. In all but the most rudimentary measurement systems, CAD models are the basis for programming inspection routines and reporting a wide variety of actionable information. What’s more, some advanced CAIIS software can leverage design intent information that is embedded within the CAD model to generate inspection programs for the part automatically, while optimizing the program for the device that will ultimately inspect it.

Sometimes this CAIIS software resides within the CAD station. More often, it is associated with a particular measurement device or is part of a stand-alone workstation for off-line programming multiple devices. Regardless of where it lives, the CAIIS software can eliminate a substantial amount of programming labor—75% or more.

A New 80/20 Rule

Inspection Planner Software <br> Inspection Planner Software is CAIIS software that interprets design intent based on GD&T data embedded in the CAD model

CAIIS packages should have the intelligence necessary to automatically create measurement programs for a range of measurement devices and probe technologies and leverage the best characteristics of the device at hand to accomplish its mission.

In general, about 80% of the information required for performing inspections—programming conventions, GDT requirements and the deliverable report outputs—is common for all inspection equipment. This suggests that most of what operators need to know to inspect parts is the same whether they are using a conventional CMM, a vision system, a multisensor system, a portable measuring arm, a CMM with laser, vision or white light sensing, or a CNC machine equipped with a probe.

The 20% that is unique deals with the physical attributes of a particular device and employing best-practice conventions to leverage these attributes. The goal of a CAISS-based system is to employ the built-in intelligence of the system to create efficient programs for any of these device types with minimal operator intervention.

Here is how this 80/20 rule of CAIIS software plays out with some commonly used types of measuring devices.

* Conventional CMMs. Because of the prominence of CMMs in metrology operations, CMM software engines have evolved into the base engines for CAIIS. The best CAIIS software for CMMs works identically across a wide range of models and brands and has evolved to include the tools to realize fundamental CAIIS objectives.
* Portable arms. CAIIS software, when applied to portable arms, allows for the use of the very same programs written for CMMs. Operators can take arms anywhere in the shop or out in the field and use them to measure the parts, assemblies and tooling immediately without the need for creating new programs.
* The 20% difference in this case deals primarily with tools allowing operators to keep both hands on the arm and still interact with the computer at a short distance. Examples include the wrist mouse, magnified screens and audible signals that tell technicians when the probe is approaching the next area of interest.
* Vision systems. The CAIIS software’s programming environment for vision is largely identical to that for a CMM. Operators make measurements of all types by interacting with the CAD model, including using ultra-precision focusing algorithms to capture data from 2-D and 3-D surfaces. They can write and edit programs in any sequence and animate probe paths on-screen for fail-safe verification. Multisensor systems even incorporate traditional CMM tactile probing tools, thus using those parts of the programs requiring tactile measurements.

Here the 20% difference involves tools that allow the operator to select values related to the unique vision requirements of lighting, focus and magnification and provide help to adjust these values when a different vision system is used. The vision implementation of one CAIIS also provides unique tools that did not previously exist, such as the ability to use the vision measurement system for ad hoc measurements or to simulate measuring microscopes and optical comparators.

* On-machine probing. The programming environment for CAIIS software used to create on-machine probing routines for a wide range of CNC machines is essentially identical to the CMM version of CAIIS software. In addition, programmers can use all or parts of existing CMM programs to create on-machine probing routines directly.

In this case, the 20% difference deals with how the software vendor implements the intelligent inspection system for machine tools. The goal here is to minimize the impact on the machine’s “making chips.” Instead of driving the probe directly, programmers use the CAI intelligent software to develop and debug routines off-line. When they are happy with the results, the software translates the program into native machine code that the CNC machine can execute.

During a measurement cycle, the machine tool immediately sends the measurement data back to the CAIIS while it quickly continues on to the next cutting operation. Meanwhile, the CAIIS package performs its analytical, evaluation and reporting tasks on a separate computer. This ensures both that the measurement process has minimal impact on the manufacturing process and that it uses the best metrology tools available.
Because the goal of inspection on a CNC machine is to make fast checks to streamline setup or detect in process errors, the programs tend to be short. This allows a single CAIIS station to manage program generation, data collection and analysis for multiple machines.

Checklist

PC-DMIS CMM inspection
Automatically generates PC-DMIS CMM inspection. This approach minimizes data input errors and reduces programming labor by as much as 75%. Source: Wilcox Associates

Leading metrology software manufacturers understand the importance of CAIIS principles and have embraced them. Because of the inherent importance of this technology, manufacturers can ensure that their CMMs and other measurement devices are able to make the most of this significant development. A checklist of actionable information can help during the decision-making process:

*  Integration with CAD. Determine the extent to which the software can leverage CAD to automate device programming. Can it import models cleanly? Can it read embedded design intent? Can it interface directly with the CAD model?
* Software commonality. Evaluate the ability of the primary software engine to interface with and control a variety of measurement devices.
* Specific-device integration. Consider how well the software operates on and improves the performance of the specific device on which it will be used.
* CAIIS orientation. Ask the vendor to describe its plans to evolve its suite of measurement software to comply with the intent of Computer Aided Intelligent Inspection Software.

As with CAD and CAM, CAIIS operates predominantly in the virtual world to achieve critical inspection objectives with a minimal amount of labor input and with greater speed and efficiency than one would have thought possible even a year or two ago. It provides bidirectional communications to realize the big picture objectives of enterprise metrology. As long as it meets device specific applications requirements, a well-implemented computer aided intelligent inspection system is always a better choice.

Sidebar

* CAIIS software can eliminate a substantial amount of programming labor.
* CAIIS packages should have the intelligence necessary to automatically create measurement programs for a range of measurement devices and probe technologies.
* Some advanced CAIIS software can leverage design intent information that is embedded within the CAD model to generate inspection programs for the part automatically while optimizing the program for the device that will ultimately inspect it.

http://www.qualitymag.com/CDA/Articles/Feature_Article/BNP_GUID_9-5-2006_A_10000000000000035336

PenFact, Inc., today announced the addition of Inspect-Write Router™, an automated work-flow management software module, to its flagship Inspect-Write software for Windows and Windows CE based mobile devices. The Inspect-Write Router uses an intelligent map to monitor, manage and process workflow. With Inspect-Write Router, management can predetermine procedures and process flows, eliminate human variances, and automatically implement ISO 9000 procedures. Like an electronic decision tree, the Router decision process is infinitely extendable, very powerful and yet very simple to implement.
Complicated procedures and processes, like manufacturing rework loops or off-line processes, are simple to implement with Router to ensure that products run through each procedure or step in a process. No matter what route a product takes, Router can ensure that the product arrives at its final destination and each interim destination along the way. Using mobile electronic inspection data in real time, the Router can identify problems early-on, saving valuable time and eliminate unnecessary re-work expenditures. The entire processing history of each product is retained in a database for subsequent analysis and product/process enhancements. Using the Router users can pre-map decision processes and know that they will be followed.
For over 10 years, the Inspect-Write systems have been deployed for paperless, mobile inspection and data collection, using powerful and flexible tools to integrate inspection data with existing databases. Wireless client software, developed with and currently used by key customers, is now available for Windows, Windows CE, Pocket PC, PC Tablets and Touch Screens.
PenFact is a recognized leader in the Data Collection and Inspection Management computing field and has specialized in pen and mobile computing for industry, manufacturing and field inspections since 1992. PenFact solutions simplify the data collection process by turning mobile pen-based computer in electronic clipboards, replacing traditional, paper-based manual inspection systems with an improved, state-of-the-art inspection and data collection system. The easy-to-use, flexible and fault-tolerant inspection and data collection process is further enhanced by a very powerful set of analysis tools enabling users to review the collected data and provide historical data review, trend graphs, SPC charts and other critical information.

http://cnc-info.blogspot.com/

Volumetric Compensation Software corrects errors in the path of the cutting tools before they occur and thereby improve the overall accuracy of the machined product.Leading engineering companies are improving the accuracy of their key machine tools with the help of a revolutionary new software product developed in Huddersfield. One such producer is Micrometalsmiths, specialists in high precision components for the microwave electronics industry, a highly competitive field in which the need to keep abreast of the latest technology is paramount. When considering how best to meet the ever higher standards demanded by their customers Micrometalsmiths were not convinced that replacing their plant would automatically give them the edge on the competition.

At around GBP 250,000 per unit, new machine centres would come with a specified accuracy only marginally better than those currently in use.It is apparent that, even with the rapid development of recent years, surprisingly little has been done by the makers to combat the most basic threats to component accuracy inherent in every machine tool. These are geometric alignment errors and thermal distortion of the machine structure.
However, upgrade they must, so Micrometalsmiths embarked upon a collaborative project with the Centre for Precision Technologies at the University of Huddersfield, UK.

With the aim of increasing output of good components in the most cost-effective way a team of experts were given the task of enhancing the company’s existing machine tools to a higher standard than ever before, even exceeding their specification when new.This ambitious plan was made possible by Volumetric Compensation Software (VCS), a ground-breaking new technology designed to correct errors in the path of the cutting tools before they occur and thereby improve the overall accuracy of the machined product.

First the performance criteria of the selected machines was measured and catalogued in minute detail. There then followed a complete mechanical and electrical refurbishment including an upgrade to the Osai series10, a controller capable of running VCS without the need for additional hardware.

There then took place a second examination by the metrology experts of the CPT, this time to determine the calibration data that was to be stored for use by VCS.Finally, the fully corrected machines were subjected to a series of exhaustive trials with remarkable results.

Volumetric error was typically reduced from 78 to 16 microns, an improved accuracy of 80%.Consequently cycle times fell by 15% and the proportion of scrap components by 30% In subsequent production trials it was found that the machines can be run faster and for longer periods of time without losing accuracy.

All-night unattended runs are now a reality and measurement cycles are executed at 3 times the speed previously possible.
Senior applications engineer Allan Kennedy said: ‘I have seen the most skilled engineers spend weeks trying to achieve this level of precision and then the machine might literally change with the weather! Not so with VCS adjusting automatically in response to temperatures measured at critical points’.

‘This is certainly the way forward for machine tool makers to meet the ever rising standards demanded by hi-tech industry.’

http://cnc-info.blogspot.com/search?updated-max=2007-01-23T01%

STEP-compliant CNC is the next-generation CNC controller, taking the STEP-NC data model as the interface scheme between CAM and CNC and carrying out various intelligent functions. At the moment, efforts are being made worldwide to establish an international standard for the new interface scheme (so-called STEP-NC), formal– ized as ISO 14649. In the near future, the new interface scheme will be completed and announced as the international standard.

Upon completion, the standard will replace the conventional scheme based on ISO 6983, so-called M&G codes. Further, the new interface scheme will impact the CAD-CAM-CNC process chain and the advancement of the CNC controller. This paper develops an integrated STEP-compliant CNC system (or STEP-CNC) based on the new interface scheme. The system is composed of five modules: (1) Shop Floor Programming System (PosSFP), (2) Tool Path Generator (PosTPG), (3) Tool Path Viewer (PosTPV), (4) Man Machine Interface (PosMMI), and (5) CNC Kernel (PosCNC). The developed system is a prototype but very comprehensive, including all the modules required for realizing “art-to-part” through the new CADCAM-CNC chain. Architecture and functional details are presented together with a realistic demonstration.

As the brain for industrial machinery, computer numerical control (CNC) is the core element in modern manufacturing systems. In spite of a great deal of technological achievement, contemporary CNC still needs further enhancement to overcome the existing drawbacks; that is, (1) it is basically an executing mechanism without intelligence, (2) it is based on low-level language [ISO 6983 (ISO 1982), so-called M&G codes], and (3) its architecture is vendor specific and black-box-styled proprietary without allowing user access.

Therefore, the next-generation CNC is required: (1) to use high-level language for seamless integration in the CAD-CAM-CNC chain, (2) to be multifunctional, intelligent, and autonomous, and (3) to have an open architecture based on modular/software implementation technology. These requirements should be accounted for in developing the next-generation CNC, for which researches are being undertaken in various aspects. In particular, a new interface scheme between CAM and CNC, often called STEP-NC, is under active progress by ISO TC 184 SCI and SC4 (ISO 2000).

The new scheme is based on the internationally standardized product model (STEP: STandard for the Exchange of Product model data), formalized as ISO 10303, as well as the process plan information. As described in the next section, ISO 14649 specifies information contents and semantics (ICS) for various CNC manufacturing processes. It is currently available in FDIS (Final Draft International Standard) version, with its final version to be completed in the near future. Upon completion, it will become a new CNC language replacing ISO 6983. The impact of the new interface scheme can be visualized in many ways. As the new data model will be an information highway for e-manufacturing, encompassing CAD, CAM, and CNC, the `art-to-part’ dream (Albert 2000) can be realized, thereby producing 3-D models in physical parts by CNC, like producing a hard copy from the printer. Significant gains are expected in the process chain of CAD, CAM, and CNC, as will be discussed in the next section. Furthermore, complete elimination of postprocessing is possible (Albert 2000). Soon, the new interface scheme will be used as a means for implementing the Internet’s B2B activities, e-design, and e-manufacturing (Hardwick 2001a, Leyrich 2001, Albert 2001, Maniscalo 2001, Teresko 2001, Hardwick and Loffredo 2001, American Machinist 2000, Hardwick 2000).

From the perspective of CNC, the new data model is very significant, providing CNC with all the information about `what-to-make’ (geometry) and `how-tomake’ (process plan) with its machine tools. In other words, depending on how the new data model is implemented, CNC would be able to incorporate various intelligent functions, which is not feasible in the conventional control based on ISO 6983. Thus, as the new language is under establishment, increasing attention has been paid to the development of new CNC based on the new interface between CAM and CNC. Major developments include Super Model in the United States and NC Prototype in Europe.

The U.S. Super Model, whose prototype was presented at the 2001 SC4 meeting held in San Francisco (Hardwick 2001b), places emphasis on the development of an `intelligent interface’ between the ISO 14649 database and CNC via XML and is implemented on the commercial systems of FB Mach and Virtual Gibbs. The demonstration was actually done with a Bridgeport CNC via G-code conversion. The European prototype, NC Prototype, presented at the 2000 SC4 meeting held in Charleston, South Carolina (Glantschnig 2000), focuses on CNC execution based on the part program written in the ISO 14649 physical file. The STEP-NC was implemented on a Siemens 840D NC Kernel interfaced with the commercial systems of Open Mind and CATIA. Interface between ISO 14649 and CNC was made via Interpreter built in CNC.

http://cnc-info.blogspot.com/search?updated-max=2007-01-23T01%3A31%3A00-08%3A00

An investment in Delcam’s ArtCAM software and CNC routers has driven a huge increase in business at Great Lakes Golf Course Products. ‘When I started here we had around 10 employees and our turnover was around $750,000 per year’, said CNC Manager, Kevin Keepers. ‘Now, we have 50 people and turn over that amount almost every month’.

‘About 80% of our products are made using ArtCAM’.

‘Without the software, the company would never have been able to grow at the pace that it has’.

Great Lakes Golf Course Products started out just over a decade ago, manufacturing recycled plastic rope stakes, hazard markers and fairway signs for local courses.

Since then, it has grown into a multi-million-dollar enterprise providing the most prestigious golf courses around the world with highly stylised, custom-tailored furnishings and amenities.

For its first six years, Great Lakes outsourced much of its custom sign work to a local sign maker and other manufacturers.

This was expensive and did not allow the company to control quality, design or scheduling.

The management realised that they could save a great deal of money and gain more control over their process by buying a CNC router and software.

After investigating a number of options, Great Lakes decided to buy an Anderson router, ArtCAM Pro and ArtCAM Insignia.

Although the company’s initial needs were met by the 2D and 2.5D capabilities of Insignia, an expansion into 3D, combined with a forecast for high demand, lead Great Lakes to conclude that investment in both versions was warranted.

In the first year, the company saved US $250,000 on work that was previously outsourced.

It has subsequently bought a second router.

‘Mostly, we do 2D signs and products, such as tee markers and information signs for each hole’, explained Keepers.

‘We also offer about 45 standard sign products which are already set up to run in ArtCAM Insignia’.

‘Recently, we have been exploring the 3D side of the software more, and looking at offering more sculpted products’, he added.

‘We are just beginning to scratch the surface of what we can offer our customers and I am excited about this end of the business’.

‘Since most of our business is custom designed, the ease of use of ArtCAM Pro and its ability to go from customer logos and artwork is a real help’.

‘I really like the tracing ability, plus the ability to load the customer’s artwork and fit clean vectors around it so that I can create toolpaths’.

‘I also like the drawing tools in ArtCAM and find I am able to do my entire design layout in the software’, he said.

‘By doing the layout and design in-house, we can get instant feedback from the customer, then make any changes needed and move onto the next version’.

http://cnc-software.blogspot.com/