Letchworth-based Maztech Precision Engineering (MPE), a prominent supplier to the F1 sector, is finding that – with F1 teams so heavily involved in the COVID-19 ventilator project – that is now making component for ventilators.

Indeed, Maztech has won an order to produce 7500 aluminium tube manifold components. The company is now running its four Mazak machining centres 24 hours a day, seven days a week, including a recently installed VariAxis i-300 AWC five-axis model.
“I had a CAM system, but it couldn’t provide suitable post-processors to communicate confidently with the VariAxis configuration,” says managing director Wayne Bouchier. “I also wanted full machine capability, so I could simulate everything, as the machine is a big investment.
“I called Open Mind and had Ken Baldwin come and give me a demonstration,” he adds. “Entering five-axis machining is never easy, but hyperMILL simplified things and made it no more complicated than necessary. After the demonstration, I was very confident in the system and didn’t need to look at any other CAM systems, so we bought our first seat of hyperMILL.”
The company now has three seats of hyperMILL: two seats with a 3+2 axis licence and the third with a full simultaneous five-axis licence. Following advice from numerous motorsport subcontractors, Maztech specified the hyperMILL Maxx Machining package for high-performance metal removal rates.
“Our programming times are at least 35-40% faster with hyperMILL,” adds Bouchier. “One example of this is the mirror function within the software. More than 30% of our work has a left and right-hand variant; hyperMILL and its mirror function is slashing programming times from hours to minutes for these parts.”
For further information www.openmind-tech.com

When the latest ProtoTRAK control was introduced it brought with it a range of benefits to improve programming efficiency and ease-of-use, all based around a 15.6” touchscreen that puts the system’s advantages at the users’ fingertips.

Now, with the latest update, users of the control on XYZ RMX bed mills can further simplify the programming of complex features, such as islands in pockets.
New and existing users can take advantage of the islands in pockets feature by utilising the optional DXF converter, which can be added at time of ordering the machine or as a straightforward retrofit for existing XYZ RMX bed mills. With this option installed it is a simple process of importing the DXF file into the ProtoTRAK RMX control. The creation of the island program, for single or multiple islands in pockets, is created in the same easy way as any other machined feature in ProtoTRAK. The program tool path can then be verified on-screen, with an estimated cycle time. For further reassurance, a 3D solid model of the machined part can be generated.
“ProtoTRAK remains at the forefront of programming technology for use on our XYZ bed mills and lathes and continues to be the ‘go-to’ control for those making the step from manual to CNC operation, and for those looking for a machine/control combination that can simplify their manufacturing processes,” says Nigel Atherton, managing director of XYZ Machine Tools. “ProtoTRAK’s popularity has continued through the current COVID-19 pandemic, with customers continuing to order and take delivery of ProtoTRAK-controlled machines; over 250 have been delivered in the past six months.”
For further information www.xyzmachinetools.com

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

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

The launch of Vericut 9.0 has brought with it several enhancements designed to increase power and improve efficiency. These new features and benefits will be showcased at the Southern Manufacturing exhibition on 11-13 February, where CGTech will be presenting from stand C215.

Gavin Powell, CGTech technical director, says: “Vericut 9.0 is smarter than previous versions, offering more robust connections to tooling databases and the latest CAM systems. Most users will experience gains in performance, as well as sharper, clearer and more realistic views of machines and the machining process. Enhancements to Vericut’s free Reviewer app also lets programmers share with others [like machinists or quality assurance personnel] how parts are manufactured.”
The new features include an enhanced graphics display. Vericut 9.0’s greatly enhanced image quality makes it easier to spot problems and imperfections in machined parts. Users can switch seamlessly between workpiece, machine or profile views, or combine them in a variety of view layouts.
Another added feature is streamlined verification. Any of Vericut’s major functions, such as auto-diff, section, and x-caliper, can be used in any view, which streamlines the verification effort and increases productivity.
In terms of ‘Force’ optimisation, Force Analyse can now be used without any prior configuration, to spot potentially dangerous machining conditions or identify under-utilised tools. Force charts has a new fill comparison option to help visualise the changes made by Force optimisation to feed rates and chip loads.
Further additions and enhancements include those involving appearance settings, x-caliper, set-up plan, multi-tool station, tool change list panel and section window.
For further information www.cgtech.com