Conversational 8055i TC/MC CNC's from FAGOR AUTOMATION

The most outstanding feature of FAGOR AUTOMATION's CNC systems is their operating friendliness, simple and intuitive, which gives them a competitive edge widely acknowledged by our customers. There are standard models with ISO and high level programming with the possibility of conversational programming that make them adaptable to both single-part work and long runs.

Conversational CNC's from FAGOR AUTOMATION (8055iTC/MC) may be adapted to the usual work method of a shop and have been designed to make intuitive programming easier for the operator; they have an interactive editor based on operations associated with each one of the processes that make up the machining of a part. The previous graphic simulation helps verify each operation and correct the data entered.

The system is programmed very easily. All the automatic operations have an interactive help, geometry defining area and other areas to set the machining conditions of the roughing and finishing stages with several editing levels or types of cycles with their own screen. This minimizes the preparation time; and any operator, without previous programming knowledge, can operate the CNC and carry out typical operations efficiently.
Its intelligent profile editor, similar to an integrated mini CAD, helps create profiles without the need for complex calculations by directly entering the values and parameters of the part, run a previous simulation and machine the part defined. If the part is too complicated, the preparation may be faster than when using an external CAD-CAM.

Telediagnosis and Setup Assistance On FAGOR AUTOMATION CNC's

FAGOR AUTOMATION has developed the Telediagnosis option to remotely control all the incidences that may occur on the machine.

Just connect the CNC with the PC of the Technical Department via the internet through a modem. This way, the technician, from his work table and at his own PC can remotely manipulate and observe the system status (CNC-drives-motors). This functionality may be used to detect PLC program errors, do a setup, or change parameters (CNC, motors mad drives), saving in travel expenses and labor of the technicians and minimizing machine down time by receiving assistance and error diagnosis immediately.

In order to facilitate the setup, it offers assistance such as the oscilloscope function and the circular geometry test.

The Oscilloscope function shows the response of the axes in time. With this feature, the signals may be seen directly at the CNC. (variables of regulation, path, feedback, etc.) without requiring external devices to check the status and facilitate the adjustments of the machine. The advantage of this feature is that the setup and the troubleshooting of incidences are faster and the diagnosis easier (even remotely) because the signals generated by the oscilloscope may be sent by fax or email.

The Circular Geometry Test may be used to cheek the behavior of the axes when doing a circle by enlarging the measuring errors of the axes. This function helps detect mechanical misadjustments and check the performance of the electronic equipment quickly while saving on additional devices.

Heartland Fabrication & Machine, Inc., Lee's Summit, Missouri, has recently installed a new Komo High-speed VR 1205TT CNC Router.

"This new CNC router, first in the U.S. in a job shop, enables us to diversify our offerings and serve new customers in a wide variety of industries," stated Mike Hudson, owner.

"A lot of companies that currently own a CNC router are industry specific and don't promote the machine due to the competitive edge they get when quoting parts."

Hudson plans to promote this machine to reach multiple industries.

The Komo features: twin spindles (24,000 rpm); dual pallets-, a 6' x 12' work surface, 3,000-ipm cut rate, .00005" repeatability and automated chip removal. It can handle aluminum, plastics, wood, cultured marble and many manmade materials.

The company will be releasing 3-D sculptured products under the name of No Limitations at a new location in Kingsville, Missouri. No Limitations will be working with many local companies to enhance their product line.

"We continually strive to stay current with the latest technologies to improve our efficiencies and service," commented Hudson as he noted the company's ongoing investment in software and training.

Heartland Fabrication and Machine, a CNC machine and fabrication shop also offers CNC turning (including y-axis) and milling, drilling, tapping, welding (MIG & TIG), CNC sawing, tube bending and light punching.

Other services such as painting, heat treating, powder coating, plating and robotic welding are also available through a wide range of suppliers.

Heartland Fabrication and Machine serves a wide range of industries in mid-America including: elevator/lift equipment; architectural/ornamental; construction; communications; trucking; railroad; agriculture; lawn and garden; food processing and custom motorcycle components.

The company is a family affair with Mike's wife, Kristi, his mother, Joann Hatch and his Father-in-law, Larry Jones, all involved in the company's operations.

High production machining is said to be enhanced by the EmcoTurn 332 MCPplus. This machine is equipped with two spindles and two turrets, which arc said to aid in the reduction of cycle time. The main spindle has 13 hp with 8,000 rpm, and the counter spindle has 13 hp with 7,000 rpm. The two 12-station tool turrets are said to provide driven tool capability at any position and produce 7 hp with 6,000 rpm.

The machine can be used as a bar machine and also offers a flexible loading system for complete automation of slugs and castings. It is also useful for one-sided parts and parts that require complete machining. The machine features a swivel loader that consists of two NC axes for axial and swiveling movement, and it can automatically load and unload workpieces. The workpiece chute at the front of the machine allows for ease in loading.

Delcam has rationalised the wide range of functionality within its PowerMill CAM system into four options: the standard PowerMill for companies with conventional machine tools; PowerMill Pro, which provides extra strategies for high-speed machining; PowerMill 3+2 for the programming of positional five-axis machines; and PowerMill 5-axis for continuous five-axis operations. All of the options can be supplied with the new integrated data repair program, PowerMill Modelling, the PS-Exchange range of data translation software, and a choice from Delcam's comprehensive selection of post-processors for all leading machine tools. Since its introduction in 1995, PowerMill has become firmly established as the world's leading stand-alone CAM system.

It has gained this position by offering a unique combination of diverse machining strategies, fast calculation times, flexible toolpath editing, and comprehensive gouge and collision checking.

These benefits, coupled with the software's easy-to-use interface, have made PowerMill the CAM system of choice for mould and die manufacture for many years.

Recent developments have extended the software's use into prototype manufacture and production machining applications, especially in the aerospace and autosport industries.

The PowerMill Pro version includes all of the additional functionality that has made Delcam the acknowledged leader in high-speed machining.

It includes extra strategies such as trochoidal machining, parametric offset machining and Delcam's patented Race Line machining.

These techniques minimise any sudden changes in direction within the toolpath, so allowing faster machining and a better surface finish, with less wear on the cutter and lower stress on the machine tool.

The 3+2 option can be added to either PowerMill or PowerMill Pro.

This includes all the milling and drilling strategies needed to maximise the productivity of positional five-axis machine tools.

It enables users to take full advantage of the benefits of reduced numbers of set-ups, shorter cutting tools, and more flexible machining offered by these machines.

PowerMill 5-Axis has been developed to allow fast, efficient programming of the most demanding machining applications, such as engine ports, blades and blisks and aerostructures.

Options for both roughing and finishing include machining to or from a point, orientation through a line or curve, programming using a reference surface and swarf machining from either surfaces or wireframe geometry.

In addition, PowerMill 5-Axis can generate a five-axis equivalent of any three-axis toolpath.

This might be necessary when a three-axis approach is being used for most of a job but where some five-axis moves are needed to avoid an obstacle or to machine as closely as possible to a steep face.

The software automatically tilts the cutter away from the obstacle by the specified tolerance and then returns the cutting angle to the value set for the overall toolpath once the problem area has been cleared.

PowerMill Modelling is a fully integrated modelling for manufacture module for PowerMill that allows users to correct all the common faults with CAD data sent for machining, such as duplicate, missing or overlapping surfaces, incorrect surface trimming, gaps between surfaces, insufficient draft and inappropriate fillet sizes.

The module operates within the normal PowerMill window and provides all the modelling tools needed by CAM operators, especially those working on the shop floor.

Being able to undertake model repair on the shop floor means that any problems can be fixed by the CAM operator.

This limits delays that would inevitably occur if the data had to be sent back to staff in the CAD office, as well as minimising the interruptions to their design work.

An investment in Delcam's ArtCAM software and CNC routers has driven a huge increase in business at Great Lakes Golf Course Products. 'When I started here we had around 10 employees and our turnover was around $750,000 per year', said CNC Manager, Kevin Keepers. 'Now, we have 50 people and turn over that amount almost every month'.

'About 80% of our products are made using ArtCAM'.

'Without the software, the company would never have been able to grow at the pace that it has'.

Great Lakes Golf Course Products started out just over a decade ago, manufacturing recycled plastic rope stakes, hazard markers and fairway signs for local courses.

Since then, it has grown into a multi-million-dollar enterprise providing the most prestigious golf courses around the world with highly stylised, custom-tailored furnishings and amenities.

For its first six years, Great Lakes outsourced much of its custom sign work to a local sign maker and other manufacturers.

This was expensive and did not allow the company to control quality, design or scheduling.

The management realised that they could save a great deal of money and gain more control over their process by buying a CNC router and software.

After investigating a number of options, Great Lakes decided to buy an Anderson router, ArtCAM Pro and ArtCAM Insignia.

Although the company's initial needs were met by the 2D and 2.5D capabilities of Insignia, an expansion into 3D, combined with a forecast for high demand, lead Great Lakes to conclude that investment in both versions was warranted.

In the first year, the company saved US $250,000 on work that was previously outsourced.

It has subsequently bought a second router.

'Mostly, we do 2D signs and products, such as tee markers and information signs for each hole', explained Keepers.

'We also offer about 45 standard sign products which are already set up to run in ArtCAM Insignia'.

'Recently, we have been exploring the 3D side of the software more, and looking at offering more sculpted products', he added.

'We are just beginning to scratch the surface of what we can offer our customers and I am excited about this end of the business'.

'Since most of our business is custom designed, the ease of use of ArtCAM Pro and its ability to go from customer logos and artwork is a real help'.

'I really like the tracing ability, plus the ability to load the customer's artwork and fit clean vectors around it so that I can create toolpaths'.

'I also like the drawing tools in ArtCAM and find I am able to do my entire design layout in the software', he said.

'By doing the layout and design in-house, we can get instant feedback from the customer, then make any changes needed and move onto the next version'.

Tuscarora Inc. has reduced the labor time for manufacturing foam samples from hours to minutes in some cases. Previously, prototypes of the company's molded foam products were carved by hand, requiring between one hour and eight hours of a skilled craftsman's time. Now, after CNC machines are programmed from CAD geometry, they automatically cut the prototypes. Programming and setup takes about 20 minutes, while actual cutting takes 10 minutes to four hours, depending on the complexity of the part. The machines operate unattended except for loading the foam stock and removing finished pieces. "It's a huge labor savings because the prototype makers are free to do other work while the machine is in operation," says Bill Brokob, manager of Tuscarora's western region technical center in Colorado Springs, Colorado. Another benefit of the CNC machines is improved accuracy, especially for the complex 3D shapes that Tuscarora's customers are now requiring.

Tuscarora Inc. is one of the world's largest manufacturers of custom molded products made from expanded foam plastic materials. The company designs and manufactures interior protective packaging and material handling solutions as well as molded plastic and thermoformed components. Its customers are major manufacturers in the high technology, consumer electronics, appliance, and automotive industries. Tuscarora currently serves more than 2,500 customers located in the United States, Canada, Mexico, and the United Kingdom from 30 locations. The company is divided into a foam molding group, an integrated materials group, a thermoforming group, and an automotive group, and an engineering services group.

Product protection and beyond

Tuscarora's foam molding group utilizes a variety of materials such as expanded polystyrene (EPS), expanded polyethylene (EPE), expanded polypropylene (EPP), copolymers such as ARCEL®, and R-MER®, and hi-heat resins. These raw materials are injected as beads into molds, then heated with steam which causes them to expand and solidify into the finished shape. The resulting molded foam shapes protect and cushion fragile products better than virtually any other interior packaging or material handling product available today. Molded foam plastics are also cost-effective, resulting in less packaging labor and smaller carton sizes. In addition to packaging applications, Tuscarora's molded foam plastics are used for products and components with a long service life. For example, foam's unique properties make it an excellent insulation component in building construction, refrigeration, and shipping containers. Recently Tuscarora has begun to offer an innovative molded foam assembly chassis for electromechanical devices that uses molded EPP foam to replace sheet metal and traditional fasteners.

The complexity of molded foam products produced by Tuscarora has increased in recent years, driven by similar changes in the complexity of its customers' products. "Nothing is square any more," says Brokob. As customers create products with more graceful curves, Tuscarora's designers must match those shapes in the packaging components they create. The use of solid modeling has helped them do this. Many customers now provide CAD models of their products. Tuscarora engineers import the models into their CAD system, Pro/ENGINEER, and design the foam packaging components around the customer's geometry.

Most customers request one or more prototypes for testing prior to having the foam parts manufactured. Previously, prototypes were produced by hand. Working from drawings, a prototype maker drew lines indicating the general shape of the part on a block of foam, then used a Bridgeport milling machine to carve out the part. Some fine-tuning was usually required, so he chipped away at the foam with hand tools until it fit the customer's product. This was a slow process, requiring anywhere from one to eight hours, depending on the complexity of the part. It was also somewhat inaccurate. "We could hold a tolerance of 1/16 inch at best working by hand," says Brokob.

Another limitation of making prototypes by hand became evident as the shape of customers' products became more aesthetic. "It was impossible to follow those curves accurately when we were cutting prototypes by hand," Brokob adds. "If we had two end caps, for instance, one for the right side of a monitor and one for the left, the two sides wouldn't always match." This problem was complicated by the fact that as the shapes were getting more complex, customers were also raising the bar on the accuracy of the prototypes. "Some of our more high tech customers have started to demand highly accurate prototypes," Brokob says. "If they want five samples for testing and verification, they want them to be virtually indistinguishable from each other. Hand samples are all different."

The drawbacks of hand production led Tuscarora to consider using a CNC machine to cut the foam samples. As the company looked into this, they found that one option was to purchase a heavy and expensive machining center primarily designed for metalworking. "These machines cost about $75,000 and are more heavy duty than we need for cutting foam," says Brokob. Further investigation revealed a more suitable alternative, a Techno CNC router from Techno-Isel, New Hyde Park, New York. This machine was designed for production routing and drilling on a wide variety of materials including wood, plastic, MDF, solid surfacing materials, and nonferrous metals. Its $25,000 price was affordable and its 0.003 inches/foot absolute accuracy and 0.0005-inch resolution and repeatability met Tuscarora's accuracy requirements. The company selected a Techno system with a 48-inch by 40-inch table size and a z-axis height extension of 19-7/8 inches.

Labor-saving process

Now, after modeling a new foam part in Pro/ENGINEER, the designer exports the solid model directly into Pro/ENGINEER's CAM program. This eliminates the step of creating drawings for the prototype maker, as was done in the past, because the CAM program generates toolpaths for the Techno machine directly from the CAD geometry. Tuscarora has set up its CAM program so that it's "almost just the push of a button," as Brokob says, to generate toolpaths. Once this is done, the CAM file is exported into the ICAM post processor that creates the actual code that drives the Techno machine. Total programming time, from when the Pro/ENGINEER model is imported into the CAM program until the machine code is complete, ranges from 10 to 15 minutes.

Another five minutes are needed to cut the foam stock to the right size and attach it to the Techno machine. The operator then hits the "start" button and the sample is then carved automatically. It takes only 10 minutes per side to cut simpler pieces, while more complex pieces may take up to four hours per side. One key advantage of using the CNC machine instead of cutting prototypes by hand is that it frees the prototype makers to do other work. The machine does not require any supervision, except to remove the finished piece and attach a new foam block to repeat the process. "It's a significant labor savings," says Brokob. "Instead of spending one to eight hours cutting foam by hand, we just attend to the machine as necessary, which takes minutes. We quite often turn on the machine when we leave for the day, and when we come back the next morning, one side of a part is done."

After prototypes have been machined, they are checked against the customer's product. This is another area where Tuscarora sees an advantage to using a Techno CNC machine. Since parts are cut directly from CAD data, the shape of a prototype matches the shape of the customer's product perfectly, something that was almost impossible to achieve in the past. "The improvement in accuracy is an important part of customer satisfaction," notes Brokob. "It also differentiates us from the other competitors who are still working by hand."

Tuscarora was so pleased with the CNC method of prototype production that the company eventually equipped each of its regional technical centers with Techno machines. The western regional center has three CNC machines devoted to making foam prototypes, and there are 10 in the entire company. Having multiple machines has been very helpful during times when one center has trouble meeting a big order. The company simply emails the machine code to other technical centers, which can be producing the parts within minutes.

Tuscarora has been pleased with the reliability of its Techno machines. Part of their reliability is due to the materials used in their construction. For example, each machine uses anti-backlash ball screws. These screws have excellent power transmission due to the rolling ball contact between the nut and screws, and this type of contact ensures low friction, low wear, and long life. In addition, the machine is constructed on steel stress relieved bases with hardened steel linear ways, and ballscrews with servomotors standard. The shaft-and-bearing system produces very smooth, play-free motion and is an extremely rigid system that produces high-quality cuts.

Using CNC machines to manufacture foam prototypes has paid off for Tuscarora in a number of ways: more efficient use of labor, more accurate samples, better satisfied customers, and a competitive advantage. "It has become more and more important that we supply highly accurate prototypes," says Brokob. "With the Techno machines, we can fulfill this requirement in a cost-effective manner."

A CNC machine allows Foam Fabricators produce the typical order of 20 sample models in two days compared to the five days needed to cut the foam pieces by hand. In addition to saving time, the CNC machine frees up engineers who previously had to pitch in and help cut foam pieces when a large quantity of samples were needed. With the exception of one person who loads the foam stock and removes finished pieces, the machine can run unattended around the clock if necessary to turn out a large order. Another benefit of automating the sample production process is that it enables the company to take on jobs it would have lost in the past. "When the shape of the customer's part was too complex to cut by hand, we had to turn away the work," says Nathan Musgrove, an applications engineer at Foam Fabricators' Jefferson, Georgia regional design and test center. "That hasn't happened since we installed the CNC machine. It can accurately cut even the most complex 3D shapes."

Foam Fabricators, headquartered in Scottsdale, Arizona, is a coast-to-coast network of 14 facilities providing shape molded foam products, packaging, and components. Its foam products are used in the packaging of items such as electronics equipment and appliances, but they can also be found in other applications such as inside bicycle helmets. The company, which has 250 employees, molds a full range of materials including expanded polystyrene (EPS), expanded polyethylene (EPE), expanded polypropylene (EPP), and copolymers such as GECET, ARCEL, and RMER. These raw materials are injected as beads into molds, then heated with steam which causes them to expand and solidify into the finished shape. Foam Fabricators also fabricates flexible materials such as polyethylenes, polyurethanes, polypropylenes, and EPS, both molded and extruded.

Samples for testing

Each of the company's regional design and test facilities is staffed with degreed packaging professionals and fully equipped with the latest in fabricating, drop testing, computerized data acquisition, and CAD systems. When a customer comes to Foam Fabricators with a new product that needs to be packaged, the first step is to work with one of the company's engineers to determine the appropriate material. Once this has been selected, the engineer uses the customer's specifications and CAD geometry to develop a rough design of the foam part. The Foam Fabricators engineer specifies the material, size, and performance characteristics for the product and uses the SolidWorks CAD system to create a 3D model of the initial concept. At this point, most customers request between 20 and 30 samples for drop testing. Some customers have this testing done by Foam Fabricators while others prefer to take the samples and do the testing in-house.

Previously, samples were produced by hand. An engineering assistant used a band saw, drill press, or hot wire to cut the foam, working from the specifications on the SolidWorks CAD drawing. This was a time-consuming process. A typical order for 20 samples took one person about one week to make. When a customer wanted an unusually large number of samples, the work was spread out over numerous people, including engineers. "This was not the best use of engineering time," says Musgrove. "But if we had to produce several hundred samples, that was how we got them done."

There was an additional drawback to producing samples by hand. Some of the shapes that customers needed were not possible to produce this way. For example, a jet ski manufacturer asked Foam Fabricators to make a bow flotation unit, a piece of foam that fits in the bow of a four-man jet ski to provide buoyancy. "This part had a lot of complex geometry and it was impossible to shape it by hand," says Musgrove. "We weren't able to make the sample, so we were unable to take on the job." A third drawback was that the handmade models were not highly accurate since the process of cutting them required some interpolation between surfaces. This was acceptable to some customers, but others wanted greater accuracy.

One of Foam Fabricators' larger customers, who typically requests a large number of samples for its extensive testing program, asked the company to consider using a CNC machine to cut the foam samples. As the company looked into this, they discovered two options: heavy and expensive machining centers primarily designed for metalworking, and inexpensive routers that could not provide the accuracy Foam Fabricators needed. Then they found the Techno Model 160 Production CNC router from Techno Isel, New Hyde Park, New York, which offered a perfect compromise. The machine was very accurate and robust which was designed for production routing and drilling on a wide variety of materials including wood, plastic, MDF, solid surfacing materials, and nonferrous metals. The price and the capabilities included in the Techno CNC system seemed perfect for Foam Fabricators' needs, so the company decided to purchase it. The technical specifications of the Techno machine they selected include a working area for the router of 59 inches by 50 inches and z-axis height of 12 inches, a vacuum hold-down table, 5 horsepower Columbo spindle and a raised gantry for large part clearance. The table features a rapid travel speed of 800 inches per minute, a z-axis cutting force of 200 pounds maximum, 0.0005-inch resolution and repeatability, and 0.003 inches/foot absolute accuracy.

Automated sample production

Now when a customer comes to Foam Fabricators with a request for a new product, the engineer creates the SolidWorks model, as he did in the past. But instead of creating a drawing, he exports the solid model directly into the Techno system's CAM program. Originally designed for metalworking, this CAM program is also well suited for foam because of its ability to generate the most complex contours with little programming effort. In the CAM program, the engineer gives the command and the software creates the toolpaths for cutting the sample. The only additional input required is information such as feed rates and cutting speeds. Total programming time, from when the SolidWorks model is imported into the CAM program until the system is ready to cut foam, ranges from 30 minutes to two hours depending on the complexity of the part.

After a piece of foam stock is fastened to the Techno machine, the operator hits the "start" button and the sample is then carved automatically. The machine does not require any supervision, except to remove the finished piece and attach a new foam block to repeat the process. With this machine, a typical order for 20 samples is completed in two days. Large sample orders no longer require the production assistance of engineers. The machine is simply kept supplied with stock and run until the order is finished.

Foam Fabricators has been very pleased with the reliability of the Techno machine. With just regular lubrication, it functions perfectly. Part of its reliability is due to the materials used in its construction. For example, the machine uses anti-backlash ball screws. These screws have excellent power transmission due to the rolling ball contact between the nut and screws, and this type of contact ensures low friction, low wear, and long life. The ball screws also make it possible to produce parts to the machine resolution of 0.0005 inch. In addition, the machine constructed on steel stress relieved bases with hardened steel linear ways, and ballscrews with servo Motors standard, which offer the best precision performance, speed capacity, and machine longevity. This shaft-and-bearing system produces very smooth, play-free motion and is an extremely rigid system that produces high-quality cuts.

Customers appreciate the faster turnaround on samples. Those who need a high degree of accuracy in their samples are noticing an improvement from the Techno machine here, too. More importantly, customers who come to Foam Fabricators seeking packaging components now have confidence the company can take on their jobs, no matter how complex the shape of their parts. Because the CNC machine imports CAD geometry and replicates that shape exactly, regardless of the complexity, Foam Fabricators is no longer limited to simpler shapes.

Having the Techno CNC machine has paid off for Foam Fabricators in a number of ways: faster turnaround on samples, more accurate samples, better satisfied customers, and the ability to take on more complex jobs. In addition, having a CNC machine helps the company compete against other injection foam molders. "Making samples on a CNC machine it becoming the norm in our industry," explains Musgrove. "With the Techno machine, we found a cost-effective way to meet this requirement."