The implementation of a CAM (computer-aided machining) system into your
CNC machining workflow process can help you produce parts more efficiently,
maintain and improve overall quality and help you win new business.
While
“automation” is the idea behind CAM software, shops around the world still
struggle to become profitable, efficient in their CNC machining process while
trying to maintain a competitive edge. Let’s
take a closer look at the subject of CAM software and how the implementation of
it can contribute to improving
programming times and your overall business.
Choosing the Right CAM Software
The
projected manufacturing demographics for CNC shops and CNC machine consumption
for 2014 tell us that shops between 1-19 employees are expected to grow by more
than 50% this year over 2013. 5 Axis CNC
milling machine tool purchases are expected to see a staggering 276% increase,
while horizontal machining centers follow at a 118% increase. These projections
tell us that companies using CNC machines are growing and they’re going to need
to automate their manufacturing processes.
Let’s
face it a CNC department without a CAM programming software is like a product
design department without CAD. The two
should be thought of as one cohesive unit.
And even though many manufacturers already have some form of CAD-CAM
implemented, not one CAM software system offers everything to meet all of their
job requirements. That leads us to the
overall workflow process …
CAD Files & Compatibility
So how does CAD/CAM software improve
production workflow? First, we have to
dissect each stage of the process. It
begins with how you acquire your part model. Most manufacturing businesses start with a 3D
model of a part either designed by you in CAD (computer-aided design) software,
from a print (paper-PDF) or a digital CAD model provided by your client. SolidWorks,
AutoCAD, Inventor, PTC-Creo, and CATIA are examples of CAD programs you might
get files from. Therefore it’s critical that a CAM system has the ability to
import or open CAD design files.
Why start from scratch. CAD systems generally have their own native
file types. Among the most common are
STL, STEP, IGES, DXF, DGN, SLDPRT and others. Some CAM packages may already have some slimmed
down CAD editing tools built in. Others offer
fully integrated plug-ins allowing them to operate within the NATIVE CAD
software, therefore reducing geometry translation issues while streamlining the
design to machining process.
CAM Job Management & Setting Up
Your Stock
Once
the part file is ready to move into the toolpath and programming stage, toolpath
strategies can be used and a program can be created in its proper sequence
allowing you to turn machining operations on and off, re-order operations, post
process and basically manage everything about the job program right within the
software interface.
So what would be the optimum order
of production in this stage of the workflow process?
1.
Creation of the stock for your part so that a
machine setup can be created
2.
Followed by your material and the tools being
used since it impacts the speed and feed settings within CNC toolpath.
3.
Workflow improvements also take place in the ability to
easily access and setup your cutting conditions and tool patterns (multi-tool
operations such as a counter bore or hole drilling with a center drill, drill
and possibly a chamfer), tool crib and tool holder data. This is important to create an error free NC program.
4. Next, you will need to access a tool library for
all of your tools. The tool library
should include all tool data, material, diameter, angle, length, labels and
more that you will be using for all machining strategies within the job tree
manager. All of this information makes
the process of setting up a job faster if you have the ability to save set up
details globally or separately from job to job. Another effective feature for saving time is the
ability to save and load machine features. Many shops do a lot of the same types of jobs.
(If you already setup your CAM for one
job, then you can use that setup for another similar job. The idea here is “automation” so every
opportunity to increase efficiency counts.)
5.
Once you have set up the stock, tools, material
and cutting conditions, next, you will want to set up the post processor for
your job. The post processor is the
translator used in the process of converting the setup data and toolpath data
and creating a numeric language (G-Code) then you will send to the machine
tools controller to physically machine the part. Think of it as a print driver for your
printer.
Important
note: Most CAM systems
offer generic post processors. Some offer the ability to customize a post
processor to meet the requirements of the controller on the machine. Check with the software provider for a library
of post configuration files, particularly the one for your specific machine
tool. Workflow efficiency can be
achieved by having the software provider assist you in the creation or
modification of posts. A correct post
processor eliminates the need for you to have to hand edit code. Thus, allowing
you to spend your time focusing on cutting parts.
Toolpath & Machining Strategies
The
next stage in the process of using CAM software involves the creation of toolpath (cutter-path)
which is the actual path that the cutting tool takes to machine the part. A CAM Tree-Job Manager will help you keep each
machining operation organized and properly sequenced so that the g-code program
produces the best possible cycle time for the job. 2, 3, 4 & 5 axis
toolpaths are all developed to produce efficient roughing and finishing cycles.
The
machine setup should already be created in the Job Tree because you already setup
your stock. A Machining Wizard is a
series of dialog boxes that step you through a process with a “Next” button
until done where a “Finish” button would close the wizard and save everything
you set for a toolpath machining strategy. When Wizards are used in the
creation of toolpath two (2) things happen.
1. New users create
programs in a fraction of time over toolpath creation without using wizards
2. Nothing is forgotten or left behind in making a
toolpath that is accurate and properly calculated based off of the tools you
setup for the job.
Toolpath
Wizards start by allowing you to choose the areas of the part to apply a
specified toolpath (planar, spiral, z-level etc) within a boundary or an entire
part, set clearances and height of rapid moves for the tool. Then you can choose the type of cutting
pattern (zig-zag or single direction cutting), cutting direction (climb or
conventional), roughing parameters, custom tolerance and cut-depth options,
lead-in and out options, toolpath linking options (how you want to connect one
path to another) and other custom machine options.
When
finished, you will automatically generate the toolpath so you can visually
inspect it. This takes place for each separate operation. If a change is needed
you can simply go back into the operation and edit it. Then re-generate the
toolpath. Once you have created toolpath for each operation, you are ready to
move into the next phase of the process.
Improvements
in workflow efficiency can also be accomplished by using high speed toolpaths.
High Speed Machining (HSM) is a
revolutionary method of cutting where the traditional hard right and left turns
in the cutting path are changed to produce more rounded or circular style
cutting movements.
In
some cases the high speed cut paths may be longer in overall length with this
type of cutting path. However, the
benefits are less tool-material collision which proves to extend the life of
cutting tools. In addition, cutting speeds
are typically increased (high-speed) which proves to reduce overall cycle
times. High Speed toolpath was initially developed for 2 Axis machining
(pocketing type operations).
Other
toolpath strategies include Advanced Roughing that allows the user to enter an
Intermediate Step variable which tells the software to rough down to the bottom
of a cavity and then come back up the outer walls stopping at each specified
intermediate level and remove the material that tends to look like a large
stair step on the walls of the part. This improves roughing quality and cuts
down on the amount of material that the finishing tool has to remove, all in
one operation.
Lastly,
workflow efficiency can be achieved in what is called, “Toolpath
Associativity.” Associativity is the ability to make a design change to a part
and automatically update toolpath operations without having to re-create an
entire job. This is highly advantageous when there are many operations within a
single job.
Simulation & The G-Code Program
The final stage in the CAD/CAM programming phase is typically the
toolpath simulation and creation of an NC program file that can be sent to the
machine tool. The simulation process allows the programmer to visually see the
process and catch any errors within the program -- gouges or collisions. Simulation also offers the ability to
calculate cycle times as well as “machined part deviation” where you can
visually inspect the part for areas that cutting tools did not fit in or cut
during the machining process.
Typically
a number-color system is used to visually detect deviation areas, tools and
machining operations. Advanced Machine Simulation allows you to use your
machines Kinematics to simulate the actual machines motion as well as the
toolpath operations.
The
final stage is the generation of the NC file that is sent to the CNC machine. This
is a critical stage of the process due to potential loss of valuable time due
to hand editing g-code programs. Once a completed post processor is created, a CAM
product should allow you to automatically create code that is clean and edit
free.
RS
232 and DNC communications is then used to send the completed program to the
CNC machine tool which is used to cut the part from the specified material and
with the specified tools that you input.
Improving Efficiency & Beyond
These
are the general stages of the CAD/CAM CNC programming process along with
examples of how you can improve the efficiency of your programming workflow by
using it. While it is easy to say that
CAD/CAM software should be simple to use, what is equally important is training.
Ask the vendor or reseller if the software
comes with training? Are there training videos that allow you to learn on your
own time? Are there local seminars or one-on-one web based training sessions
available for you to learn on the fly and on your own time? The more options
the better which includes the ability to achieve operator certification as a
professional.
We
hope you found this article useful in helping you either be more efficient with
the CAM system you already own, or if you’re in the process of investigating
one, to know what questions to ask and the benefits that come with owning one. For more information email info@cadcamconnect.com, or call
1-844-CADCAM1.
About CAD/CAM Connect
With over 100 years combined experience in the CAD/CAM
Manufacturing industry and literally thousands of contacts, CAD/CAM Connect
hosts an online network of trusted hardware, software and service vendors --
connecting buyers to top suppliers via our sites.
Products and services ranging from CAD and CAM software, CNC machines, 3D printers, CAD training, reverse engineering, rapid prototyping, FEA-CFD simulation software, translators, ERP, data management, 3D part catalogs, contract CAD help, job placement and more. www.cadcamconnect.com and www.cadcamreviews.com
Products and services ranging from CAD and CAM software, CNC machines, 3D printers, CAD training, reverse engineering, rapid prototyping, FEA-CFD simulation software, translators, ERP, data management, 3D part catalogs, contract CAD help, job placement and more. www.cadcamconnect.com and www.cadcamreviews.com
WE'RE HIRING NEW LIVE WEBCAM MODELS!
ReplyDeletePROFIT MORE THAN $10,000 EVERY WEEK.
JOIN AS A BONGA MODELS WEBCAM MODEL TODAY!