Mastercam 2022 centres on turning

CNC Software Inc, developer of Mastercam CADCAM software, has released Mastercam 2022 turning solutions. From accepting and programming any CAD file to Dynamic Motion roughing and precision finishing, Mastercam 2022 gives users a variety of options to turn parts exactly as required. Mastercam 2022 features new mill-turn support, and enhancements to 3D turning tools, stock diameter and more.

With Mastercam 2022, users can now: define reusable holder assemblies; create collections of adapters, extensions and holders; and store them as an assembly. In short, users can save time and avoid errors by creating reusable assemblies of modular components. These assemblies can be stored in a library and used for the creation of full 3D lathe tool assemblies.

When defining stock dimensions in job set-up, a new button lets users specify the outer or inner diameter by selecting an arc or radial face. After selecting the button, users are returned to the graphics window where they can select an arc or radial face. Programmers can also select an edge. Mastercam automatically reads the proper diameter value from the selected geometry.

The 2022 version of Mastercam introduces steady-rest support for mill-turning, which allows users to precisely position and simulate steady rests throughout the machining process, adding part support capability to turning, milling and part-handling operations. This includes new component types, enhanced component libraries, dedicated operations for each type of steady rest, part handling strategies and simulation features.

The sub-program support from other Mastercam products has also been added to the mill-turn module. Users can create sub-programs for depth cuts and hole-making operations.

For further information
www.mastercam.co.uk

Experience the limit of feasibility

EMO visitors will see Kern (Stand C21, Hall 1) undertake live machining demonstrations to show how injection moulding tools for filter housings (used in respiratory masks) can be machined with a precision of less than 1 µm and surfaces in the single-digit nanometer range. This level of precision and surface finish will be demonstrated on the Kern Micro HD machining centre that is now available in the UK from Rainford Precision.

The parts will initially be roughed with the Heidenhain optimised contouring machining (OCM) option and then brought to the highest quality at critical points with five-axis jig grinding cycles. After machining, the manual polishing of such precision parts is an industry-standard process, however, as the Micro HD achieves surface quality in the single-digit nanometer range, manufacturers can omit this step.

For further information www.rainfordprecision.com

ModuleWorks releases version 2021.08

ModuleWorks has released the 2021.08 version of its CADCAM software components. This second ModuleWorks release of 2021 contains new and enhanced features across the entire product range, including new performance-improving features for multi-axis machining, two-axis machining and PrimeTurning.

Automatic rest finishing for multi-axis machining automatically applies a rest-finishing cycle to any remaining non-machined areas that could not be reached by wall and floor finishing operations. The wall and floor finishing operations carry information about which areas can be machined and which cannot. The new rest-finishing cycle automatically extracts this information from the operations and creates a rest-machining area that can be reached using a different tool with automatic tilting. Operators can choose which areas to machine and which curves to use as guide curves.

Two-axis roughing and finishing in a single operation is for wireframe engraving, enabling operators to add a final profile pass to roughing operations. This capability accelerates the engraving process because roughing and finishing are now performed in a single operation. By selecting one of the new sorting options for the 2D wireframe engraving cycle, operators can adjust the sequence in which a part’s features are machined, making it easy to apply the engraving pattern to a wide variety of scenarios.

The clean-up pass is a new feature for the PrimeTurning roughing cycle. After running the roughing cycle with the arc-entry operation, unwanted material is sometimes left in the corners of the stock. The new clean-up pass automatically removes the unwanted rest material to ensure clean, high-quality roughing.

For further information
www.moduleworks.com

New innovations from Vollmer

Vollmer (Stand E18/F13, Hall 2) will be presenting its sharpening machines and digital solutions for the manufacture of cutting tools (both carbide and PCD tipped). Among the highlights on show at EMO will be the new VHybrid 260 grinding and erosion machine, as well as the VLaser 370 laser machine, which will make its first live appearance. There will also be a world premiere for the new VGrind 360S tool grinder.

The VGrind 360S can machine carbide tools with a diameter up to 25.4 mm. Depending on the machine kinematics and the tipping of the grinding wheel packages, it can even be used for tools up to 150 mm diameter. Furthermore, incorporating wear-free linear induction motors on all three axes lowers maintenance costs while demonstrating higher surface quality for the tool.

For further information www.vollmer-group.com

Turning centre helps subcontractor blossom

After winning a prestigious power generation project to turn critical stainless steel components, subcontract manufacturer Fairbrother & Grimshaw (Engineering) Ltd recognised that it needed to reconsider its machining strategy to improve cycle times and shop-floor throughput. The upshot was the arrival of a Nakamura-Tome AS200LMYSF turning centre from the Engineering Technology Group (ETG).

Based in Cherry Tree on the outskirts of Blackburn, Fairbrother & Grimshaw has a long-established relationship with ETG that dates back to buying recognised brands for more than a generation, prior to some brands being rolled into the ETG portfolio. In 2017, the relationship with ETG really blossomed for the company when it acquired two Quaser MV184 three-axis machining centres with Nikken 4th-axis rotary units from ETG.

Commenting upon the previously acquired Quaser MV184 machining centres, Fairbrother & Grimshaw managing director Neil Grimshaw recalls: “We needed to replace an ageing Bridgeport machine and, after doing our due diligence, we bought a Quaser MV184 from ETG. We liked it so much, we had a second one installed. The quality of machines from ETG is second to none and this is equalled by their customer service and support. That is one reason why, when we looked at a new turning centre, we opted for the Nakamura-Tome from ETG.”

The 12-employee company had won a long-term contract for 50-off stainless 316 components each month; and the challenging parts required three operations on a turning centre followed by 4th-axis machining on one of the Quaser MV184 machines. Fairbrother & Grimshaw recognised an opportunity to expedite the process with one-hit machining, while acknowledging that if its existing CNC turning centre had a breakdown, completing the monthly order would be problematic. Despite extensive market research, the Nakamura-Tome AS200LMYSF won the day with its twin-spindle configuration, long-bed specification, milling capability and Y axis that provides a 90% increase in turning length. With a longer Z-axis travel and a Hydrafeed barfeed, the new addition supports the production of complete parts either via its 8-inch chucking capacity or 65 mm automated barfeeding capacity.

Installing the Nakamura-Tome AS200LMYSF delivered results immediately, as Grimshaw confirms: “The Nakamura is like having four machines in one. By using the Y-axis milling and the sub-spindle facility, our parts are coming off the machine in one-hit. The benefits include a drastic reduction in set-ups, the elimination of second-ops and an overall cycle time reduction of more than 50%.”

He continues: “One-hit machining reduces the manual handling of parts, reduces human intervention and improves the overall quality and consistency of a batch of parts. We’ve recently installed a new Axiom Too CMM and the parts coming off the Nakamura are not only high in quality with excellent surface finishes, but the dimensions are consistent with zero deviation.”

With nine CNC machining centres and four CNC turning centres, the new Nakamura-Tome AS200LMYSF is bridging the gap between the two departments, permitting more milling work to be completed in a single operation in the turning department. This is gradually increasing capacity in the milling department as fewer parts require secondary milling operations.

Grimshaw says: “While we primarily bought the machine for the power generation part, we are witnessing similar savings on other legacy work that we’re transferring to the Nakamura. For example, we have a regular 1000-off series run of washers for the rail industry that was previously two operations. By transferring this to the Nakamura, we are machining the parts in one-hit, alleviating milling work from our 4th-axis Quaser and reducing our cycle times by more than 30%. Furthermore, with the barfeed facility, we can run the Nakamura unmanned until the batch is complete – saving on labour costs. Likewise, we have a die component for the food industry that is required in volumes of less than 100-off and the two turning operations and three milling operations are now a single operation on the Nakamura.”

The objective is to move more work to the Nakamura-Tome AS200LMYSF, but for Fairbrother & Grimshaw there is no urgency in expediting all its work to the new acquisition.

“We are moving legacy components onto the Nakamura when the opportunity arises but, as a busy machine shop running a three-shift pattern, our shop-floor team has to gradually build their confidence and competence on the machine,” states Grimshaw. “In this respect, ETG has been absolutely fantastic in supporting our machinists with any queries or issues they may have. Another appealing factor with the new Nakamura-Tome AS200LMYSF is the large-screen CNC control system. Young engineers want to be using the latest technology and the Nakamura has this in abundance.”

As the company gains confidence with the Nakamura, the benefits will continue to surface for Fairbrother & Grimshaw.

“Although we bought the Nakamura-Tome AS200LMYSF for a particular job, we knew it would reap rewards with other components,” says Grimshaw. “As that comes to fruition, we are seeing set-ups, cycle times and manual input continually decreasing. Additionally, we’re seeing throughput, quality, consistency, surface finishes and even staff motivation improving as a result of the investment.”

“As our experience with the new machine grows, we have the opportunity to both alleviate the capacity burden from our milling department by completing more milling work on the Nakamura, and look for new types of work,” concludes Grimshaw. “We can already see the added potential this machine is giving us to enter new markets and take on more challenging work. This really does offer us some exciting opportunities, while making our business even more competitive.”

For further information
www.engtechgroup.com