Newsletter, courtesy of partner MAL and distibutor Terranic Systems

The newsletter below is re-produced courtesy of our partner MAL, whose product is distributed by Terranic Systems Inc. More information is available on the website,  and they also have an good blog. This article gives more information on blade machining. Note, some of the formatting has defied blogger's authoring software and as hard as I try, some of the text has escaped the main frame.

The ModuleWorks Blogger.

Newsletter TERRANIC SYSTEMS | MAL INC

Dependable Solutions, Proven Results Blade Machining Steam turbines are jewels of power generation industry. According to Wikipedia, they alone constitute about 90% of all electricity generation in the Unites States. Steam turbines extract energy from high pressure, high temperature steam via blades attached to a rotor. Blade geometry is a major factor in turbine's performance. Its intricate design improves energy generation making turbines more efficient and productive. In today's digital age, design engineers utilize various tools to improve blade shapes, which are now even more difficult to be produced with required specs. Sandvik Coromant's application development team develops know-how in tackling difficult production tasks like blade machining. The team combines their expertise in machining with the latest digital tools  to come up with best practice guidelines. Every aspect of machining - from fixture design to tooling and tool path strategies - is meticulously analyzed, compared, tested and proven before implemented at a customer site. Productivity Improvement Striving to achieve the best process possible, the team worked with us to utilize MACHpro Virtual Machining software (demo video), which was set up to keep consistent chip load without overstressing cutting tool or machine. Original 5-axis NC program was thenautomatically optimized using MACHpro's optimization module. After two attempts, the team accomplished an overall productivity increase of 57% (three roughing, two semi-finishing operations combined) MACHpro's automatic feed optimization module captured and eliminated inefficient feed rates along 5-axis tool path where cut geometry greatly varied. The original NC program used one feed value, which was good for the heaviest cut, throughout entire operation. However, MACHpro's intelligent feed optimizer was able to calculate exact load on the tool at any point along the tool path, hence successfully varied the feed rate to boost material removal rates while avoiding tool overloads. Two snapshots given below show how MACHpro adapts feeds based on varying tool load along the path during roughing. Left Photo Problem - Tool is overloaded.  Remedy - Feed is reduced from 2674 to 2458 mm/min.  Outcome - Tool and spindle overloads are prevented; insert life is prolonged.  Right Photo Problem - Tool is lightly loaded, under-utilized. Problem - Tool is lightly loaded, under-utilized.  Remedy - Feed is increased by about 300%.  Outcome - Tool and machine are fully utilized without overstressing any component; insert life is maintained. Copyright © 2012 Terranic Systems Inc., All rights reserved.  You are receiving this email because we value your business and help you spur growth by implementing the latest lean manufacturing solutions.  For more information, visit Terranic Systems | MAL Inc  Our mailing address is:  Terranic Systems Inc. 201-1932 West 1st Avenue Vancouver, BC V6J1G6 Canada

SharpCam Partner with ModuleWorks for Simulation

We recently announced SharpCam as a new partner for Simulation and 3-Axis toolpath generation. SharpCam are relatively new to the market and distribute via the Internet. We worked with SharpCam to integrate ModuleWorks Simulation in to their product. The press release is re-produced below. SharpCam also use our 3-Axis Machining technology, so look out for more on this in a future blog.

ModuleWorks, the leading supplier of CAD/CAM components for 3 - 5-Axis toolpath generation and simulation have confirmed their partnership with European CAM supplier, SharpCam. SharpCam, delivered exclusively through the Internet, is an easy to use application for programming milling machines.

The latest releases of SharpCam include ModuleWorks state-of-the-art simulation component to show simulation of material removal during the manufacturing process, providing instant and accurate feedback to the customer and ensuring safe and optimal toolpaths

Mr. Julian Paphitis, SharpCam CEO has been talking about the reasons behind the new partnership with ModuleWorks and comments, "We had spent many hours developing our own simulation and had basic functionality working, but always at the back of my mind was that I knew that it was not 4/5- Axis capable. Before we started our in house development we had contacted a number of suppliers but the cost and lack of interest in getting involved with a start-up company like ourselves was very disappointing. However, once we were contacted by ModuleWorks, things were very different. They went the extra mile, allowing us to use DirectX as opposed to OpenGL and offered a viable licensing arrangement.  The end result is now an integrated solution that we are very pleased with, taking SharpCam to the next level! We have also been able to re-direct development resource into doing what we do best; easy to use programming. The support offered during integration was exceptional, we could not have asked for more and we look forward to continued collaboration with ModuleWorks."

SharpCam join the growing list of more than 50 CAD/CAM vendors who have partnered with ModuleWorks to provide machining and/or simulation technology to their customers. Data from global industry consulting firm, CIMData, show ModuleWorks technology used by more than 60% of the leading CAD/CAM suppliers.

Yavuz Murtezaoglu comments “We’re pleased to have SharpCam as a new partner. It is always interesting to work with the newer vendors on the market and we’re pleased that SharpCam has had a good experience working with ModuleWorks. The project highlights the benefits of the partnership with ModuleWorks, enabling SharpCam to deliver industry proven Simulation technology to customers in a short period of time.”

Until the next time..

The ModuleWorks Blogger.

ModuleWorks Technology for Dental Manufacturing

In this edition of the ModuleWorks blog, Dr David Plater, Technical Director for ModuleWorks, looks at how the ModuleWorks Dental component is being applied in the Dental manufacturing sector. The ModuleWorks library is tailored for the dental industry and provides high performance 3-5 Axis machining coupled with fully featured Machine Simulation.

Simulation rendering of bridge

The use of CAD/CAM in the dental healthcare industry is a fast growing area and recent years have seen many advances in the use of CAD/CAM software. Its use is now standard practice in the manufacture of copings, crowns, inlays, veneers, bridges and dental implants. CAD/CAM has dramatically shortened lead time for dental restoration – from days or even weeks to a matter of hours.

Constant Cusp Finishing

CAM is a key requirement as 3-Axis milling and 5-Axis milling is used to machine the dental components. 3-Axis milling is the primary machining strategy used for roughing and finishing from a range of materials. 5-Axis machining is often required to finish the dental components with complex undercut surfaces.  Simulation is also an important tool, helping to validate the process and ensure right first time.

Margin Line Finishing

Taking the example of a dental bridge, the manufacturing process is broadly split into three stages; Roughing, Finishing and the fine detail. 

• First roughing, followed by rest roughing is applied to both the occlusal and cavity side of the bridge. 
•  Next, the bridge is finished using a range of 3-Axis toolpaths, mostly constant cusp strategies and 5-Axis machining on the undercut areas. 
•  The bridge is completed with the fine detail provided using rest finish and margin line finishing.

To find out more about the ModuleWorks Dental component, check out the website and download the free fact sheet at www.moduleworks.com/dental.

New release, ModuleWorks 2012.4, is on the way

We're just in the process of finalizing the release of the latest version of our of CAD/CAM components for toolpath generation and simulation, version 2012.4

As always, the new release offers a range of new features across the product range, further expanding capability for 3-5 Axis machining and simulation.
 

ModuleWorks is at the forefront of 5-Axis machining and Simulation technology, providing the toolpath generation and CNC simulation components behind many of the popular CAM systems available today. 
 

The latest release introduces a broad set of new features across the products range. Highlights are shown below:-

 

4 and 5-Axis Machining

SWARF with relief cut

SWARF with external corner loop

The 2012.4 release introduces improvements to SWARF machining, providing finer control over tool motion.  New for 2012.4 is the option to minimize rotary motion as the tool approaches a singularity condition, providing smoother toolpath and better surface finish.  Corner handing is improved with different options for motion around corners. Internal corners can be rounded or sharp and optional relief cut applied External corners have sharp, roll around or loop options. Fanning distance may also be specified as the distance used to transition the tilt around corners.

STL based 5-Axis Roughing

A new 5-Axis roughing strategy has also been added which takes triangle mesh geometry as input. Given floor, walls and ceiling geometry, the toolpath is automatically generated.

Multiblade toolpaths now offer dynamic lead angle to optimize tool approach angle within a given range, providing best tilt and maximum material removal.

Collision avoidance has been improved and now gives the option to eliminate collisions that could not be resolved by the regular collision checking strategies.
 

3-Axis Machining

Adaptive Roughing Feedrates

3-Axis Roughing now offers automatic adaptive feedrate.  Toolpath generation takes tool engagement into account and varies the feedrate within a given range, improving tool life and maximizing material removal. Roughing will also differentiate climb and conventional cuts and allow different stepovers and adaptive feedrate control to be applied on the different cut directions.   
 

2½D Roughing

3-Axis Roughing and profiling strategies have now been extended to handle prismatic wire frame geometry for 2½D applications. Roughing and profiling strategies are currently supported. 

A separate Stock model tolerance may be specified. Using a bigger (lower) tolerance value will give faster toolpath generation and usually stock tolerance is not critical to the final part.

Simulation

Wire EDM simulation

Simulation now supports a length based mode, in addition to the NC and time based simulation types. This will simulate the entire toolpath at constant speed, making it easier to visualize actual tool motion.
 

Stock transfer now supports bar work, where multiple parts are machined from bar stock. Simulation will show the cut off and transfer to secondary spindle along with the advance of the bar for the next operation.

Wire EDM application benefit from improved simulation with support for 2, 4 and 5-Axis wire cutting operations.   

We recently ran a series of webinars to highlight the new features, please feel free to contact us for a recording if you want to know more.

Until the next time

The ModuleWorks Blogger