FEATURE ON CNC & CAM

RO-RA relies on VERICUT simulation software

As an aerospace supplier, RO-RA Aviation Systems GmbH is very successful, especially in the production of complex, high-precision and difficult-to-machine components, primarily for the aviation industry. With demands for high-quality components, it is essential that processes are safe and stable. For maximum process reliability and the best-possible performance, RO-RA uses VERICUT CNC simulation, verification and optimisation software, including the VERICUT Force milling module. The result: no more machine crashes and time savings of up to 25% per component.

Among the success factors at RO-RA is the digitalisation of development and manufacturing processes, which includes the networking of all engineering and testing processes.

“By setting up digital twins in product and process development, we achieve significant improvements in time-to-market,” explains managing director Helmut Wiesenberger.

By way of example, RO-RAmanufactures complex connectors made of aluminium for aircraft fuel lines, in which the machining rate is around 95%. Previously the company experienced machine crashes despite CAM simulation, which of course resulted in downtimes and service calls. In order to avoid this and ultimately increase process reliability, RO-RA introduced CGTech’s VERICUT simulation and optimisation software in 2018 after a selection process.

“In order to produce such sophisticated milled components efficiently and economically, we were looking for a software solution that simulates our NC programs in advance and checks them for any problems, such as collisions,” says Patrick Fellinger, head of engineering at RORA. “The fact is, CAM simulation only simulates the toolpaths and not the actual NC code. With VERICUT, we get a virtual machine and a machining digital twin, which means every travel path that we program is checked for 100% process reliability.”
For further information www.cgtech.co.uk

Chemical simulation software tests new composites

Software company Molydyn is to use chemical simulation to test new composite materials, in collaboration with the University of Sheffield Advanced Manufacturing Research Centre (AMRC) and Bitrez, in order to make the testing process more sustainable.The project aims to use molecular modelling to develop a viscosity modelling capability for Molydyn’s accessible web simulation platform, Atlas, to help design better composite materials while reducing costs and environmental impact. Building upon previous collaborations with the AMRC, the project is utilising funding from an Innovate UK Transformative Technologies grant.

Chemical simulation allows researchers to test new materials quickly with virtual experiments, screening out prospects that are unfit for the lab. This saves laboratories time and money, while proving to be a more sustainable method –testing materials virtually requires no disposable gloves, single-use plastics or solvents.

With the rising price of electricity and raw materials, composite material manufacturers are feeling the pinch becauseinfusing viscous, honey-like resin into the fibres often requires high-pressure pumps and heating. However, resin tested for an optimised viscosity would flow like water and reduce the cost, environmental impact, and difficulty of manufacturing composite parts.

Matthew Bone, chief executive officer at Molydyn, says: “It’s good to be back working with the AMRC again, and tackling a major problem like viscosity. We’re hoping to expand Atlas and give materials scientists a tool to help them design better composite materials. Composites are shaking up many sectors with the environmental benefits of light-weighting, so we’re keen to help get better composites to market faster.”

The AMRC, part of the High Value Manufacturing (HVM) Catapult network of research centres, will conduct empirical lab testing from its innovation cluster in Rotherham.
For further information www.amrc.co.uk

Facilitatingseamless digital manufacturing workflow

ModuleWorks, a provider of software components and solutions for CADCAM systems and CNC machining, has introduced the Manufacturing Data Exchange Specification (MDES). The new specification aims to enhance the efficiency of manufacturing workflows by enabling seamless data exchange across different platforms and processes.

MDES is a new, open data exchange specification for the manufacturing industry. It increases the interoperability of different hardware and software systems across all stages of the product lifecycle, from design and planning to production and quality control. The free-to-use specification enables any company to adopt MDES as a universal language for the digital representation of machining assets such as tool components, assemblies, fixtures, stocks and set-ups, as well as their mounting in machine tools.

Unifying the digital representation of machining assets in an open specification has the potential to simplify and accelerate data exchange by minimising the need for data bridges between different proprietary systems. This would also reduce software development costs and dismantle adoption barriers for new equipment, encouraging manufacturers to leverage the benefits of the latest technology on the market.

Yavuz Murtezaoglu, founder and CEO of ModuleWorks, says: “Over the past 20 years, ModuleWorks has been developing digital manufacturing software in partnership with CAM system developers, machine tool builders and CNC control manufacturers. This puts us in a unique position to understand the importance of a common data exchange specification for the industry, and to develop a specification that meets the needs of different stakeholders.”

The new specification is compatible with the existing industry standards ISO13399 (Cutting tool data representation and exchange) and DIN4000-190 / DIN4003-190 (Tabular layouts and 3D description of fixture devices).
For further information www.mdes.info

CAM for laser machines reduces machining times

GF Machining Solutions has released version 1.12.5 of its CAM software for laser texturing, engraving and micro-machining. This latest release includes two new major features: 3DCurves and FlexiBlast, incorporated within LaserDesign technology.

3DCurves allows users to increase their design capabilities while eliminating potential undesirable optical effects on laser engraved parts. It provides an innovative approach when creating fine line patterns and textures. Users no longer need to go through the traditional hatching process based on a grayscale bitmap and, thanks to 3Dcurves, can now engrave directly with a single continuous laser path following each individual polyline.

This new technology allows customers to create unprecedented designs applied in 2D with GF Machining Solutions’ Laser P range of machines. It also offers the possibility to create curves virtually on complex 3D parts and mould tools and inserts with the Laser S range. The technology uses polylines as opposed to images, which suffer limitations due to their bitmap resolution, to orientate the laser vectors in the local co-ordinate system.

FlexiBlast builds on GF Machining Solutions’ signature blasting capabilities by combining them with a grayscale image, controlling its intensity. For each individual pixel, it is possible to apply 216 shades of grey, each corresponding to a specific blasting intensity. This feature offers the potential to render high-definition photo-realistic images on any material. Moreover, it gives users the ability to increase the depth perception with very shallow textures, which reduces production time without any hardware modification. Fading textures and morphing are possible without altering surface geometry.

The technology provides advantages such as high definition with photo-realistic rendering, the creation of very fine textures with a significant rendering of depth and shallower textures for easier plastic de-moulding and faster machining times.
For further information www.gfms.com

Manufacturing analytics software supports 30% growth

A precision machining company has achieved 30% growth in turnover following the installation of a manufacturing analytics platform. Chesterfield-based Sterling Machining installed FourJaw’s manufacturing analytics platform on 14 of its CNC machines to support and inform its continuous improvement strategy.

Co-owner and production manager Andy White says: “We had an ERP in place but no way of accurately measuring jobs and their profitability until they were finished. If a job took longer than expected, we couldn’t see why. FourJaw’s machine monitoring system has given us valuable data that we use to understand machine utilisation, operational efficiency and profitability. In the past 12 months our business has grown from £3.8m to £5m turnover.”

FourJaw’s MachineLink IIoT device is suitable for easy and quick self-installation on any manufacturing machine, regardless of brand, type or age, which makes it suitable for small and medium-sized businesses that prefer a low-cost, no-fuss ‘plug-and-play’ solution. By monitoring and analysing machine data, FourJaw enables manufacturers to make machines run productively and profitably.

“Initially, the guys on the shop floor were a little reluctant but soon became interested to see how it worked,” says White. “It didn’t take long for them to become competitive, wanting to get the best machine efficiency scores, resulting in utilisation going from 75% to 100%. This means that we’re making more products with the same resources, lowering the cost of manufacturing and therefore improving profitability.”

Since installing FourJaw on its machines, the team at Sterling Machining has improved many processes, informed by the platform’s accurate real-time data. For example, the team uses historic data to see how long similar jobs have taken and uses this information to quote more confidently for future work.
For further information www.fourjaw.com