Siemens introduces AM Path Optimizer for NX

Siemens Digital Industries Software has launched Additive Manufacturing (AM) Path Optimizer, a beta technology integrated in NX software, to help customers solve overheating challenges and help reduce scrap and increase the production yield of powder bed fusion manufactured parts. This latest extension of Siemens’ end-to-end AM solution feeds the digital thread, informing each step of the industrialised AM process.

Building on the Simcenter Additive Manufacturing Process Simulation solution announced in November 2018, AM Path Optimizer complements Siemens’ strategy for the digital twin of the manufacturing process and addresses errors originated from sub-optimal scan strategies and process parameters. These can lead to systematic failures due to overheating, which can cause scrap and inconsistencies in component quality.
Siemens has had success demonstrating this beta technology with Trumpf as a partner.
“With the AM Path Optimizer, Siemens and Trumpf can push the industrialisation of additive technologies further forward,” says Jeroen Risse, AM expert at Trumpf. “In our demonstrations we saw an improvement of geometrical accuracy, the elimination of re-coater errors caused by overheating, as well as a more homogenous surface quality. Also, the scrap rate is expected to be reduced significantly.”
The technology uses a novel approach, combining physics-based simulation with machine learning to analyse a full job file in few minutes before execution on the machine. In addition, the system can help reduce printing costs and enable the printing of components that are nearly impossible to achieve today.
“AM Path Optimizer will have a great impact on the use of AM for powder bed fusion manufactured parts,” states Zvi Feuer, senior vice president of manufacturing engineering software at Siemens Digital Industries Software.
For further information www.siemens.com

Open Mind adds AM to hyperMILL

The latest addition to hyperMILL CADCAM software from Open Mind is the Additive Manufacturing suite, which is designed to satisfy the requirements of industrial 3D printing processes. As a universal software solution, hyperMILL – together with this option – will provide efficient hybrid processing with simultaneous additive and subtractive processing on a single machine platform.

hyperMILL Additive Manufacturing opens up an array of flexible options for DED (directed energy deposition) and WAAM (wire arc additive manufacturing) processes in terms of five-axis simultaneous processing. Both laser-based powder nozzle machining heads and wire arc additive manufacturing can be controlled using the software for selective material deposition, as well as conveniently programmed and automatically simulated for collision avoidance.
Open Mind’s hyperMILL suite now allows the potential of additive manufacturing to be exploited using powder-bed fusion (PBF). If 3D-printed parts do not offer the desired precision, or support structures have to be removed, the components can be machined afterwards by means of five-axis machining. Even hard-to-reach areas can be machined in a secure manner using hyperMILL, says Open Mind. As an integral part of the process chain, the CADCAM system supports reworking of this nature. The printed components are analysed, milled to size and examined.
Additive and subtractive manufacturing processes are increasingly being combined in a single machine tool for hybrid manufacturing. With this in mind, hyperMILL now enables users to program the cladding and the milling routines together. True-to-detail application and removal simulation, as well as stock tracking between individual machining steps, assure process reliability.
For further information www.openmind-tech.com

NCSIMUL digital twin helps Nuclear AMRC

Being able to import completed NX assemblies into G-code simulation software is proving to be a valuable time-saver for the Nuclear Advanced Manufacturing Research Centre (Nuclear AMRC). NCSIMUL, part of Hexagon’s Production Software portfolio, guarantees that finished G-code sent to CNC machine tools, is 100% accurate, and collision free.
“It gives us an exact representation of what’s happening on the machine,” states Tom Parkin, production engineer at the Nuclear AMRC. “Having this digital twin is absolutely vital in ensuring cutting paths are correct.”

And the software’s ability to import full NX assembly files is an added bonus. “CAM and simulation systems generally aren’t particularly user-friendly when it comes to positioning individual models,” says Parkin, “but being able to take an NX assembly, including a fixture, stock model and the final part, is particularly beneficial. Without it, we’d have to import single models one at a time, import the fixture by itself and position it, and import the stock model and position that in relation to the fixturing. NCSIMUL, however, allows us to import a full assembly file from the NX package straight into the simulating environment. From there I can select where my datum positions are, select the tooling, put the NC program in, and run the G-code simulation.”
This point is reiterated by principal production engineer Andrew Wright. “Some of our set-ups are quite complex, in that they have multiple pieces of stock and workpieces, plus fixture items. So being able to take in a file containing full assemblies which have been designed in CAD and not have to manipulate them, saves us considerable time.”
For further information www.ncsimul.com

Brake manufacturer accelerates with Esprit

As the manufacture of carbon brake disks for aircraft requires specific skills, each of the 200-plus employees at Safran Landing Systems in Villeurbanne, France, play one of three complementary roles. Some weave carbon fibres, while others perform the heat treatment necessary for the conglomeration of the fibres into strong, compact stock with final forms that will be machined by the company’s third group of employees.

Increasing orders in the global aerospace industry motivated Safran to consider ways to become more efficient and responsive, with emphasis on the need for the company to improve its manufacturing methods to make a more reliable product.
MHAC Technologies, Safran’s partner in machine programming and a local distributor of Esprit CAM software, suggested the company implement Esprit, a full-spectrum CAM system for CNC programming, optimisation and simulation. With MHAC’s help, Safran installed Esprit’s SolidMillTurn Production Plus software, which can handle C-axis index and rotary milling, Y-axis index milling, B-axis index milling and 3rd rotary axis index milling. The system includes SolidMillTurn Traditional and Advanced, and SolidTturn Multispindle, a two-axis turning add-on to support multiple spindles.
When programming Safran’s CNC lathes and three- to five-axis milling centres, Esprit software enables a quick set up due to automatic macros that define the machining origins, offsets and machining assemblies. Patrick Gaydoux, an experienced programming technician at Safran, praises “the cloud-enabled KnowledgeBase integrated in Esprit, which automates and optimises the choice of optimal machining strategies based on a company’s accumulated best machining practices”.
Macros developed by the machine manufacturer and managed by Esprit software can automate and optimise operations according to the type of machining to be done and the stock measured directly on the machine. MHAC Technologies develops made-to-measure post processors for the specific machines in Safran’s workshop.
For further information www.espritcam.com

Schunk robot gripper in spotlight

Just before Christmas, the University of Sheffield officially opened AMRC Cymru, a £20m research and development facility in North Wales.

Airbus AMRC building is officially opened with AM Mark Drakeford along with Lord Barry Jones, Airbus Paul McKinlay, AM Ken Skates, Professor Koen Lamberts, University of Sheffield and Coleg Camria’s David Jones Pictured: One of Airbus Robots delivers the celebration ribbon

As a member of the AMRC, Schunk UK played an integral role in the opening ceremony, holding the ribbon with a Schunk gripper for Wales’ First Minister Mark Drakeford to cut the ceremonial ribbon. Mounted on a Kuka AGV, the new Schunk EGH Co-act gripper is the latest addition to the Schunk Co-act gripper family, and is a flexible system for gripping and moving small to medium-sized workpieces in the areas of handling, assembly and electronics.
For further information www.schunk.com