February 2008 Edition

CAD/CAM

Efficiency Wins Work

The owner of Innovative Alloy discovered the advantages of CAD/CAM when he bought his first machine; it's been a love-love relationship ever since

In the information technology business, lazy programmers are prized employees. Not because they don't work hard, but because they write the minimal code to get the job done — and they get it done with efficiency and elegance. Jerry Piesch, owner of Innovative Alloy, Lebec CA, is far from lazy, but after being introduced to CAM software, he's a convert to doing things the efficient way.

Piesch began Innovative in 1996 with a Bridgeport 3-axis mill that came with a version of FeatureCAM 2D, from Delcam, Salt Lake City. After mastering the software, he hasn't looked back.

Innovative now has Fadal machines and a Haas SL20 turning machine used to produce aftermarket motorcycle parts, catalytic converter dies, castings, and even guitar parts. Piesch said he depends on FeatureCAM 3D software to keep him ahead of his competition.

Pilot Process

When he upgraded to the 3D version of the application, he wasn't sure of his mastery of the software. Rather than possibly ruining a production piece, he tried it on a piece of wood. It proved to be a success.

"I'm now so familiar with the software that I don't have any doubt that the part is going to turn out well," he said.

The CAM software saves him hours of programming time for each part file that comes into his shop. He uses the time savings to boost production. Another benefit is that the machining exceeds customer requirements.

The enhancements to FeatureCAM 2008 help Piesch get programs onto the shop floor.

"It makes the creation and editing of tool paths for any CNC machine quicker, easier, and more flexible, which is a big help to us," Piesch said.

Piesch said that for him, part programming time with FeatureCAM was less than half of that required for conventional CAD packages, due to the software's ease of use. The CAM package lets Innovative automate machine motion simulation and data management.

Feature Work

With feature-based machining, a part program is created using features that describe the part, from simple holes, to complex pockets, to turned grooves. The machining operations are automatically generated. Feature-based machining frees Piesch from creating and managing each machining operation. And since there are fewer objects to manage, he completes part programming faster, and with fewer errors.

"I have also used part simulations for quoting work," he said. "After the part is simulated, I check the details list to see machining time and other factors. I know I have won some jobs using this technique."

Used as building blocks to describe a complete part, features define the shape of the part; the faces of the part; the size and shape of pockets, slots, bosses, and grooves; the locations and types of holes; and whether those shapes have chamfered or rounded edges. Piesch can revise a program by changing one or more individual parameters, such as depth or radius, and the software updates the entire part.

Features also describe how to produce the shapes on Innovative's CNC machines, such as how and where material removal should occur; cutting depths; whether to use climb cutting, to spot drill, or center drill; and preferred machining strategies for roughing and finishing.

When a part is constructed of features, the CNC programming process becomes automatic.

According to Piesch, as features change, the end-product is updated, so he isn't required to start over as a part changes.

Programming automation occurs not only within a feature on a part, but also between features in the part process plan. As Piesch creates features, FeatureCAM constructs a process plan based upon analysis that reduces tool changes, rapid distance, and tools used.

Less Programming

"This lets us increase efficiency by spending less time programming parts, and helps us use more efficient methods on the shop floor," Piesch said.

"I know I have won some jobs using this technique."

"One of my customers has us do various sizes of its catalytic converters," he said. "When they send over their solid model part file, I import it and choose only those sections of the part file I need to machine for that order; I already have the basic part design file in FeatureCAM. To create a new program, I only have to pick the new segment of the program. There's no need to create a new part program for different orders. That cuts programming time to a fraction of what a new program would require.

"The hours the application's FeatureRECOGNITON saves benefits us because we're a small shop and I do all the machining. If I spend less time in the office at a computer, I can spend more time machining, and shipping parts," Piesch said.

Solid modeling assists Piesch. He said he can create and review the fixture design and part to see what the part should look like and how it will machine to avoid errors when cutting metal.

Advanced machining strategies speed calculation rates of 3D tool paths for Innovative. The faster and more frequent the calculations, the more consistent the load on the cutter. Sudden changes in the cutting direction that put excessive loads on the tool are minimized, as are slower feed rates. For Innovative, the result is longer tool life.

The spiral path milling strategy enhancement to FeatureCAM helps in milling molds. Rather than the conventional approach of machining down the job, level by level, spiral path milling keeps the cutter in constant contact with the job, eliminating air moves. It minimizes dwell marks and protects the cutter and machine tools.

"I've used FeatureCAM for so long that I almost believe I've lost the ability to go in and use the machine software to create part programs," Piesch said. "Even for a small detail like a hole, I'll program in FeatureCAM, not the machine software, because it quickly renders a program I can count on."

Piesch downloads programs from his desktop to his machine tools.

"FeatureCAM is one of the reasons I am still in business," Piesch says. "It lets me spend more time in the shop making parts than in the office scratching my head, trying to figure out how to make a part. It's been a deal-maker for my business." Delcam

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THESE ARE A FEW OF MY FAVORITE THINGS

For Jerry Piesch of Innovative Alloy, FeatureCAM has found a multitude of uses and efficiencies. Here are a few he found most useful.

Solid Modeling

 I do a lot of parts that require the use of soft jaws with special shapes milled into them for holding parts, therefore I will create a solid model of 6" vise jaws that have not been milled yet and then save them in the part library. When I have a new job that requires milling a certain shape for holding my part, I open the vise jaws file, save the solid model as my stock, and I'm ready to create a new shape.

Surface Milling

I do catalytic converter dies for one customer. They design the male and female form with just enough clearance for the thickness of the material between them. In order to provide better tool life, on the female form blocks I like to run a little extra clearance. Therefore, after picking all my surfaces for milling, I leave allowance to -0.003". This assures that my female form will be cut 0.003" more than the solid model. That saves a huge amount of time rather than the need for any new design work in the customer's file.

Translucent View

This function lets me see through a customer part. It's great for inside O-ring grooves, checking the depth of the cutting tool, and other interior features. I also like to rotate my part so I can see areas I can't see otherwise when watching regular simulation; for instance in top view, isometric, and other views.

NC Code

FeatureCAM adds all the parameters of the job that I am manufacturing right into my NC Code: part name, material size, and a list of the tools for a specific job. This is useful when I run the same job at a later time. I just look at the beginning of the program to determine which tools I need to get the job done. FeatureCAM's ease of use is impressive. I let my two sons Justin and Nick play around with the software, and they produced NC Codes of their own design within a couple of hours. With no coaching.

What do you think?
Will the information in this article increase efficiency or save time, money, or effort? Let us know by e-mail from our website at www.ModernApplicationsNews.com or e-mail the editor at pnofel@nelsonpub.com.