Unveiling advanced CNC and digital solutions

At the recent BI-MU exhibition in Milan, Fagor Automation took the opportunity to shine the spotlight on its next generation of industrial automation and CNC technology, as well as its range of services, such as Fagor Digital Suite.

According to Fagor, Digital Suite 5.0 simplifies and streamlines decision-making in smart manufacturing environments. With integrated digital dashboards, real-time data visualisation and predictive maintenance capabilities, the company says that Digital Suite 5.0 offers a complete digital solution for industrial machinery.

Among other highlights on the Fagor stand was HMIelite, a next-generation HMI that optimises CNC systems for improved performance and user experience. Available in several models, including CNC 8070elite, 8065elite and 8055elite, Fagor says that HMIelite provides cutting-edge control technology, whether working with complex machines or high-precision applications.

Another key product on display was Series3, the company’s encoder solution known for its robust performance and functional safety. Certified with SIL2, this series is suitable for industries that require high safety standards. A stand-out feature of Series3 encoders is Fagor’s 3STATECH technology. What makes 3STATECH innovative is its ability to detect any contamination on the measuring standard, with its redesigned optical system and smart image processing algorithms. This capability offers an extra layer of reliability and ensures accurate performance, even in challenging conditions.

With over four decades of expertise in CNC systems and feedback solutions, Fagor says that its products are designed not just to meet today’s needs but to anticipate future manufacturing challenges, helping businesses transition seamlessly into the era of Industry 5.0. Whether looking to optimise CNC processes, implement digital transformation or improve safety standards, Fagor Automation has the tools and expertise to support.

More information www.fagorautomation.com

ModuleWorks 2024.12 software components

ModuleWorks has unveiled the 2024.12 release of its software components for digital manufacturing and digital factory. This latest release of the ModuleWorks SDK includes various new and enhanced features aimed at increasing safety, toolpath generation efficiency and part quality. These features contain enhancements across multiple components, ranging from multi-axis surface finishing to simulation and many more.

For example, the four-axis swarf mode has seen a significant improvement to achieve optimal geometric accuracy. This enhancement addresses the challenge of machining complex surfaces, such as cylindrical cams, using flank milling on a cost-effective four-axis machine. Traditionally, aligning the tool with the surfaces when using a tool smaller than the slot has been difficult. However, the new algorithm now accounts for kinematic limitations during the initial toolpath calculation, eliminating the need for four-axis enforcement in post-processing and reducing the risk of inaccuracies.

With the ModuleWorks 2024.12 release, this enhancement brings several benefits, including improved component accuracy, reduced machining costs and greater flexibility in selecting tool diameters.

Another upgrade involves multi-axis deburring. Until now, it was difficult for users to eliminate all the simultaneous five-axis moves from a 3+2-axis deburring toolpath. This issue would result in unpredictable motion on the machine tool during operation. In the 2024.12 release, ModuleWorks has improved 3+2-axis deburring to provide 3+2 orientation with minimum five-axis motion. As a result, users benefit from enhanced machining safety and accuracy.

Also worthy of note is an enhancement that focuses on three-axis finishing, where users often struggle to manually identify and define areas that can be machined by different sections of barrel tools. A new feature in ModuleWorks 2024.12 assists users by automatically identifying the steep and shallow areas on the part.

More information www.bit.ly/3PmdncW

PECO on right track with VISI CADCAM

As one of the world’s major manufacturers of model railways, PECO is a forward-looking family business that started trading back in 1946. Initially concentrating the production of trackwork for model railway enthusiasts, the company has grown exponentially. To support its expansion, the Devon-based company relies on VISI CADCAM software from Hexagon at its design and manufacturing facility.

PECO’s toolroom manager Simon Cockerham says: “We use numerous licences of VISI across our processes, from concept through to final press or mould tool creation. In addition, we use VISI to generate laser-cut wooden kits featuring surface textures, and create instructions that guide enthusiasts and users on how to assemble the equipment.”

He continues: “VISI has always been very good for our business as it focuses on what we need to do the job. Some of our previous software packages caused issues due to tight component tolerances and the nature of the machining processes that we have to undertake to achieve the geometries required in our press and mould tools.”

VISI incorporates modules such as: modelling; analysis; mould design; flow; electrode design; die tool design; 2.5, three and five-axis toolpaths; blanks; and reverse. This capability provides PECO with the facility to create solid models, design, analyse, validate and prepare mould tool geometries, and perform pre- and post-production analyses of plastic parts.

With dedicated modules for creating electrodes, designing dedicated progressive die and press tools, comprehensive machining strategies, and even reverse engineering of editable solid models from scanned data – VISI provides a complete package for the company.

“Another key reason why we use VISI is the complexity of our products,” says Cockerham. “We need jobs to be right first time.”More information www.bit.ly/4iX3f8h

Vericut introduces two AI-powered tools

Vericut, a global specialist in manufacturing software, is releasing two AI-powered tools: Vericut Intelligence (VI) and Vericut Assistant (VA). The company says these new resources enhance how users interact with and gain knowledge from Vericut’s suite of software products.

VI is an AI-driven solution that serves as a knowledge hub for all of Vericut’s software offerings, including Vericut, Composites, Vericut Optimizer, and a variety of other modules and features. The resource is accessible to everyone, providing in-depth information on any aspect of Vericut’s software, from basic inquiries like ‘what is Force?’ to more detailed questions about specific functionalities like ‘what is X-Caliper?’

While VI focuses on providing product knowledge, VA assists users with the practical application of Vericut software. VA offers step-by-step guidance on the use of various features, answering how-to questions directly within the software. For example, users can ask, ‘how do I use Auto-Diff?’ and receive precise instructions. As VA evolves, it will also start to interact directly with the software, allowing users to perform tasks like ‘add a tool with these criteria’.

“Our goal with VI and VA is to simplify information access, making it intuitive and easy for users to deepen their understanding of our software,” says Gene Granata, director of product management at Vericut. “The new tools deliver intelligence that’s incredibly useful and relevant, streamlining the user experience and setting a new standard for product knowledge accessibility.”

“The introduction of VI and VA marks the beginning of a long-term strategy to integrate AI into Vericut’s products, with the ultimate goal of maximising productivity while ensuring privacy,” adds Frankie Cates, director of information and security at Vericut.

More information www.vericut.com

New lease of life for large milling machines

The retrofit of Heidenhain TNC 320 controls and drives to three large Elgamill travelling-column bed mills at the Swansea factory of subcontractor Afon Engineering have improved their reliability and performance. It has been an object lesson in how mechanically sound machine tools built in the late 1980s can be given a new lease of life for a fraction of the cost of investing in new equipment.

Engineering director Andrew Beaujean says: “The project has given us more confidence to take on a much broader variety of contracts and is bringing in new business as a result, such as evaporator tube plate machining.”

The refurbished machines at Afon have beds measuring 12, 10 and 8 m respectively in the X axis. The mid-size model, when it was installed in 2009 with an earlier Heidenhain TNC 355 control, was the first CNC machine on site. The other two Elgamills, which arrived five and 11 years later, were fitted with a TNC 155 CNC system. Two smaller, as-yet unmodernised machines from the same manufacturer are also on the shop floor.

The upgrade to the new controls has considerably reduced programming times by up to 50%, making more jobs economical to undertake. A benefit of having identical TNC 320s on three Elgamills is that, from the operator’s perspective, all keys, buttons and switches are in the same place, so swapping between machines is seamless. Moreover, the overall cost of the refurbishments was within budget at approximately £350,000 for all three machines, an order of magnitude less than purchasing three new machining centres of similar capacities.More information www.heidenhain.co.uk