Machining: definition
What does machining mean?
Machining is a manufacturing process that consists of giving shape to a raw material, such as metal, plastic, or wood, by removing material to obtain a finished part with precise dimensions and specific characteristics. Automotive, aerospace, energy, electronics… Machining is one of the most commonly used methods in industry.

The main objective of machining is to create complex shapes and finished surfaces with high precision. This may include making cavities, grooves, threads, holes and flat or curved surfaces, depending on the technical specifications of the final product.

One of the main advantages of machining is its versatility. Machining can indeed be used to produce a wide range of parts, ranging from simple individual components to more complex assemblies. In addition, machining is suitable for different types of materials, including ferrous and non-ferrous metals, engineering plastics or composites.

Focus on machining machines
The machining process involves the use of a machine tool , such as a lathe, milling machine, grinder, or drill, which is precisely controlled to remove material in a gradual and methodical manner. Different cutting tools, such as drill bits, countersinks, reamers and blades, are used depending on the specific needs of the machining operation.

Over the years, machining has evolved with the introduction of new technologies and techniques. Modern machine tools have become increasingly automated, incorporating digital control systems and advanced sensors to improve the accuracy, productivity and safety of machining operations. Nowadays, most companies use numerically controlled machine tools (MOCN) , backed by a computer system (CAM), which makes it possible to partially or totally automate the machining procedure.

What is a machining technician?
A machining technician is a trained professional who specializes in performing machining operations. He is responsible for preparing and setting up the machine tools, choosing the appropriate cutting tools, setting the cutting parameters and performing the machining operations . To achieve this, he must be able to read and interpret technical drawings, select the correct machining methods according to specifications, and use machines and measuring instruments with precision to ensure compliance with tolerances. required.

In addition to their technical skills, the machining technician must have a solid understanding of materials, machining processes and safety standards . He must be able to analyze potential problems, resolve manufacturing defects and take corrective measures to ensure the quality of machined parts. With the rapid evolution of the machining industry, machining technicians are also required to keep up to date with new technologies and advances in the field . They may indeed be required to work on advanced machine tools, integrate numerical control systems and use computer-aided design (CAD) software to optimize machining processes.

What are the 4 basic machining operations?
Shooting
Performed on a lathe, this technique makes it possible to manufacture cylindrical, conical parts, or with complex shapes such as threads or grooves. The workpiece is clamped on a rotating spindle, while the cutting tool is moved along the workpiece to remove material and give it the desired shape.

milling
Milling involves using a rotary cutter to remove material and create complex shapes such as grooves, flat surfaces, pockets, or contours. Milling machines can be used for 2D or 3D machining, depending on the movements of the part and the cutting tool.

Note that the milling of flat surfaces consists of using a special cutter to obtain smooth and precise flat surfaces. Planar surface milling is often used to produce bearing surfaces or reference surfaces in workpieces.

Drilling/reaming/tapping
Drilling is an operation to make holes in a part using a drill bit. The bit rotates and enters the workpiece, removing material to create a hole of precise diameter and depth. Drilling can be done on a conventional drill or on a more advanced machine tool.

Complementary, tapping is an operation used to create internal threads in a previously drilled hole. A tap tool is used to cut thread-like grooves inside the hole, allowing bolts or other threaded items to be screwed in.

Finally, reaming aims to enlarge and improve the quality of a previously drilled hole in a part. This operation is typically used when looking to achieve very precise tolerances, high-quality surface finishes, or specific dimensions.

rectification
Grinding is a high-precision machining operation used to achieve very smooth surfaces and precise dimensions. This operation is carried out using a grinding machine which uses abrasive wheels to remove small quantities of material and obtain very tight tolerances.

These machining operations are the basis for many other more advanced machining techniques. Depending on the specifications of the part to be machined, the required tolerances, and the desired geometric characteristics, it is important to choose the right machining operation.

What future for machining?
Several major trends are to be noted in the world of machining.

Increased automation
Machining is increasingly automated, with the introduction of robots and intelligent manufacturing systems. Modern machine tools are equipped with advanced sensors, digital controls, and artificial intelligence technologies to optimize production processes, improve accuracy and speed, and reduce human error.

3D printing for machining
3D printing is increasingly used in machining, especially for the manufacture of complex parts. Metal 3D printing technologies in fact make it possible to produce parts with complex internal geometries, which reduces the need for additional machining operations. The integration of 3D printing and traditional machining provides more flexible design and manufacturing opportunities.

Hybrid additive manufacturing
Hybrid additive manufacturing combines 3D printing with traditional machining. This approach makes it possible to build parts with complex structures through 3D printing, and then perform machining operations to obtain finished surfaces, precise tolerances, or additional features.

The integration of artificial intelligence
The use of artificial intelligence (AI) in machining is expanding. AI can be used to analyze real-time data from machine tools, optimize cutting parameters, detect manufacturing defects, and improve the overall efficiency of the machining process.

Sustainability and eco-responsibility
The machining of the future will also focus on sustainability and eco-responsibility. Companies will seek to reduce their environmental footprint by adopting more energy-efficient machining practices, using recyclable materials, and optimizing processes to reduce waste.

✓ The software is compatible with my clients’ file formats
This seems obvious, but it is nevertheless a point to check because it is not uncommon for CAD/CAM software to use proprietary formats. To meet your needs, the TopSolid software solution uses the Parasolid exact geometric modelling core, well-known and frequently used in CAD/CAM. Thus, by choosing TopSolid, you will be able to read and write in all open formats on the market, which guarantees the interoperability of your files with the main systems used by your contractors and subcontractors.

✓ I have the opportunity to test the software before buying it
Compulsively choosing your software is out of the question. It is necessary to prepare your project by precisely identifying its needs, using specifications. From there, a good practice is to identify a typical part of your production, if possible complex to better understand the capabilities of CAD/CAM software to be tested. You must then make a pre-selection of 4 or 5 CAD/CAM software and request a free demonstration. Most serious software companies offer this option.

✓ I was fully satisfied with the demo
The demo request should allow you to compare the different software selected and evaluate their technical features with regard to your typical part and your needs. The first element to consider is the ability of the software to efficiently program the manufacture of the submitted part. The second is the software’s ability to adapt to your existing environment. Interoperability is key in this sense: the software must be able to retrieve any type of CAD file and connect to other ERP and CAPM software, reliably and efficiently. At the end of the demo, no grey area should remain. So do not hesitate to put the person in charge of the demonstration to the test! Rely on your specifications to be sure that the software will be useful to you on a daily basis.

✓ The software works properly with my machines
CAD and CAD/CAM needs are directly related to the company’s activity. It is important to understand that a design office of decoration products will not have the same needs or objectives as a toolmaker, an aircraft manufacturer or a manufacturer of special machines. However, it does not matter whether a company is equipped with a CNC wood, sheet metal or mechanical park: it needs a CAD/CAM solution adapted to its needs. It is therefore necessary to favor software adapted to its activity, which integrates relevant business functions.

✓ I have the possibility to customize and upgrade the software
Each profession has its own know-how, and each company has its own processes: the CAD/CAM software must be able to take into account the specific procedures that make up the strength of a company. Don’t settle for a standard solution: opt for a customizable CAD/CAM solution. Only in this way will you be able to capitalize on your know-how, in order to benefit from the best productivity potential.

✓ I inquired with users of the software
The reputation of a solution is an important element to consider. In this sense, what could be better than reviews from real users to help you identify the potential of a software? Read user reviews, look at customer cases, and try to see what are the positive or negative elements that stand out from one user to another, focusing if possible on user reviews from a sector similar to yours.

✓ I have the necessary computers and network infrastructure
Before positioning yourself on a software, remember to ask all the necessary technical questions. For example, you should ensure hardware compatibility between the software and your computers, taking into account the required operating system and the type of graphics card needed, to anticipate any additional costs. Rely internally on the specialists in the field, to be sure not to forget any aspect.

✓ I know how many licenses I need and for how long
License purchase, rental… When it comes to CAD/CAM software, several business models exist. If the rental system, in the form of a subscription, may seem attractive at first glance, it is however necessary to be wary. Admittedly, the company has the possibility to pay in instalments but cumulated over time, the price of the subscription is often higher than the purchase price of a license. In addition, in SaaS mode, you are not in control of your data, since it is the software publisher who has total control over it. In the event of a temporary network outage, you will not have access to your CAD/CAM solution. The purchase of a license allows for its part to offer tailor-made, thinking long-term. By paying the price of the software at once, the company becomes the owner and keeps perfect control over its data. However, this solution requires basic skills for installation, handling and updates of the software. This is why it is advisable to choose a publisher that offers real support and training sessions.

✓ I know the cost of the software and maintenance contract
Beyond the cost of the software and the maintenance contract, it is necessary to ensure what the license includes in terms of accompaniment and support. Aware that the implementation of CAD/CAM software represents a major undertaking, TOPSOLID supports companies from the preliminary phase of the CAD/CAM project, to the implementation and handling of the software. Thus, each TopSolid offer includes a complete training offered to your users, within a TOPSOLID agency. As a CAD/CAM licensee, you then benefit from unlimited customer support via the TOPSOLID hotline, for a minimum period of 6 months. At the end of these 6 free months, you have the option to subscribe to a specific maintenance contract, which will give you unlimited access to dedicated customer support. At the same time, you will have regular access to new training courses to make the most of the evolution of TopSolid’s CAD/CAM software. In addition to in-depth business expertise, TOPSOLID strives to develop a close relationship with its customers, to allow you to go further, always faster.

This article was originally published on CAD/CAM: the essential checklist to make the right choice of software! (topsolid.com)

A new generation solution integrated into the TopSolid environment

Specialists in Virtual Reality, TOPSOLID VR is going to be offering TopSolid’Virtual, a new generation collaborative 3D visualization software solution based on Weviz. It features real-time project reviews, 1:1 design reviews, realistic interactive 3D presentations, simplified project validations and multi-user capabilities. This solution is based on the Unreal software engine from EPIC Games.

TopSolid’Virtual is perfectly adapted to many different industries: design, engineering, machining, architecture, marketing, education and so on. Not only does it allow visualization and manipulation in virtual reality, the tool is simple and can be used by employees with no experience. It also has the specific capacity to allow everyone to access 3D files without special software.

A NEW OFFER AVAILABLE IN A FEW WEEKS

More than 95% of manufactured products are now designed with CAD. It was therefore essential for TOPSOLID to expand its real-time imaging and virtual reality solution. TopSolid’Virtual is aimed at CAD/CAM teams and, most importantly, at all other departments within your company. It is the ideal tool for bridging the gap between, for example, the technical teams and the marketing department, as it lets you present the designs created with CAD software in a concrete and visual way.

This visualization solution is a logical extension of the software equipment that TOPSOLID already offers to its customers as part of the TOPSOLID Integrated Digital Factory.

“We are proud to present TOPSOLID VR and to welcome the Weviz teams to TOPSOLID,” says Richard Lamure, President of TOPSOLID. “It was important for us to acquire a virtual reality solution because these tools are becoming indispensable in the market. This new acquisition is part of our external growth strategy aimed at offering more services to our customers. It allows us to reinforce our position as the ‘French leader’ in the CAD/CAM software market, with innovations designed and developed in France. “

1) “Tool Management”: What do we mean by that?
Tool management encompasses physical tool management in a workshop as well as all the technical data attached to each tool and component used in your manufacturing process. This is usually handled by a dedicated software designed to assist machine parts manufacturing by automatically loading technical data into the CAD/CAM system as well as managing tools’ and components’ physical inventory.

Tool management becomes even more important when considering next-generation CAD/CAM software. Based on 3D modeling, machine kinematics, advanced simulation and many other tools needed to create high-precision machined parts, a lot of data is generated to ensure that the products coming off your assembly lines are of the highest quality.

This data needs to be accurate, up-to-date, available, and ready to be retrieved. This way, you avoid inaccuracies and save time and money in the overall process, which also means improving profits.

2) Challenges that come with tool management
Since tools and components for manufacturing processes are a very large and complex topic, one of the biggest challenges is the interface to get the 3D data into the CAD/CAM application. Indeed, in addition to the 3D graphic, a tool also contains many parameters and functions in space that form the basis of the toolpath algorithm in CAM. If there is a single faulty parameter, the operation in CAM is invalid and cannot be generated.

Another challenge is that most of the available solutions on the market only work by pure database application, which means that you only get a graphic view (and not a 3D visualization) of the part to be produced. This makes it confusing and complicated to use, especially for occasional users. Most of these solutions do not facilitate 3D data management or even offer a functional interface for CAM applications.

3) The benefits of a good tool management solution
If all the data for each tool and component are centrally managed, any information can be retrieved at any time and from anywhere in the company. In addition, good tool management ensures that all references and back references are stored, not only for transmission to the CAM system, but also for all existing NC programs. This allows you to better plan for new programs as well as improve change management.

A good tool management solution also provides you with a real time picture of your tool magazine on the shop floor, allowing you to directly synchronize your machine magazine with your CAM environment. Therefore, by centralizing production data, you can optimize your workshop organization and increase overall productivity by:

· Reducing machine set-up lead time

· Improving traceability of program modifications

· Providing precise tool location

· Monitoring the use and wear of tools

4) Advice for beginners
If you are thinking about implementing a tool management system, you should look for a solution that will help you to efficiently manage your tool components, your assembled tools, their life cycle, and is running on a single data source that is always easily and readily accessible. But above all, it should be adapted to your activity!

The tool management solution you consider should be able to adapt to your existing processes, workflows, and growth strategy by being completely modular and scalable. Think big in order to be able to implement additional modules in the future!

You should also be able to build on your existing NC data. As you are not starting from scratch, your tool management solution should automatically take into account your existing data in an intelligent way. Indeed, you cannot afford to stop production while you fill in and set up the database. The system must be able to connect existing data, learn and expand while using it, and integrate it step by step.

5) Why TopSolid’ShopFloor can answer your needs in terms of tool management
What makes TopSolid really unique on the market is that there is no interface between the tool management system and the CAM application. TopSolid’ShopFloor is a product that is completely based on TopSolid’PDM as are all TopSolid solutions. Thus, components and tools are controlled by revision, oriented towards properties and BOMs like a “standard” part or assembly and are fully associable with all modules available in TopSolid (CAM, Design, Draft, …).

To easily create components and assemblies, TopSolid provides libraries to create your own components from fully parameterized ISO 13399 models. Of course, you can also import and use supplier data. TopSolid’ShopFloor supports all data, even data from other tool management systems.

Searching for components and creating assemblies are simple and can be managed via TopSolid’ShopFloor Tool Manager. The fully graphical drag and drop assembly process is very user friendly and is a great help in daily activities.

It’s not a secret, just an industrial logic: process fluctuations during the machining of a part are detrimental to competitiveness and profitability. They are a source of errors, machine stoppages, scrapping due to manual adjustments and controls, resulting in colossal time and material losses. As a result, quality and labor costs skyrocket, delivery delays occur, and poor traceability. A probing system allows us to understand these process variations and correct them to achieve consistent, automated, and productive machining.

Now, let’s go further and imagine a CAD/CAM solution that allows you to program and simulate your probing cycles – preparation, control, quality, safety – guarantees optimal reliability… This is the package offered by the TopSolid’Cam CAD/CAM solution, which we invite you to discover …

I – Machine probing: what are we talking about?

The touch probe is a tool that works mostly by switches, which, when activated by contacting a workpiece surface, allows for adjustments and control during machining operations. The geometric data returned is accurate and repeatable. This means that it shows any errors found by probing the workpiece in different directions and any deviations when examining a workpiece repeatedly in the same order.

The objective of probing on a machine is to obtain parts that conform to requirements and optimize the machining process. The probe is used, in general, for dimensional measurements (metrology) or on three-dimensional coordinate measuring machines (CMM) to calibrate parts or tools. However, it can also benefit the entire manufacturing process, as the dimensional information collected during machining is valuable. We are thinking of the automatic adaptation of machine tools for the entire machining process, the limitation of human interventions, increasingly precise production, and the possibility of dimensional control directly on the CNC machine tool.

An obvious must-have, it would seem …

II- Machine probing with TopSolid’Cam: why?

In the era of (almost) manual operation, the operator would have to read the part print and enter coordinates for probing, inheriting all the risks of misinterpretation and typing errors that this manual process entails.

With TopSolid’Cam, the control and verification processes are carried out before and after the machining operations. The simulation and trajectory of the probe are carried out in the digital machine environment, safely and securely, using the part’s actual geometry as points to probe.

Efficiency and reliability meet!

III- What are the benefits of this feature?

The benefits of using TopSolid’Cam to program machine probing starts with preparation and control, both are definitely “quality” oriented.

Example:

During the preparation operation in the machine space, the part is precisely positioned within a zone of plus or minus ¼” from the position programmed in TopSolid’Cam. The software identifies the part and detects the presence of blank stock or fixtures, such as a screw or clamp, in order to avoid risk of collision. Finally, the location measurement is done automatically.

The generated machine output control report, identical to one produced by a CMM, considers the geometric defect of the latter: the tool is thus corrected dynamically. Therefore, the machine is dynamically corrected, and a correct dimension is obtained without interpretation, reading, or typing errors. With TopSolid’Cam, precision is at the heart of the control process.

Quality as a result: obtaining a conforming part in the geometric state of the machine is 100% guaranteed!

IV- More productive probing with TopSolid’Cam

Using the TopSolid’Cam solution, the operator avoids possible errors when defining part origins, the risks of crashes or collisions due to the presence of undesirable elements in the machine, or the scrapping of parts resulting from an erroneous tool offset correction, are all eliminated.

You stop wasting time. Your material costs, direct labor and shop support costs, are all reduced – therefore you deliver – on time: your machine output is better, and your productivity is radically improved!

Conclusion

Because it combines programming and simulation and is perfectly integrated with the Post Processor, TopSolid’Cam represents a unique solution on the market to problems related to probing. Machining is more consistent, qualitative, and productive by reinforcing automation and minimizing human intervention during the process.

In short, TopSolid’Cam boosts your machining capacities, both in terms of quantity and quality, enabling you to respond better to the needs and requirements of your market. This means that you can accept new contracts, work on innovative concepts and possibly offer your teams more proactive technical roles. Think about all the possibilities!

TOPSOLID SAS, the world leader in CAD/CAM publishing software for Metal and Wood industries, announces the opening of a new strategic partnership, TOPSOLID India, as part of its objectives to consolidate its footprint and have a closer relationship with its customers in India. TOPSOLID SAS footprint represents more than €100 M with 600 people Worldwide. In 2019, the company’s turnover was €47M with 320 employees.

Richard Lamure (CEO of TOPSOLID SAS) explains: “India is one of the largest growing industrial market in the world with major players in Aerospace Automobile Manufacturing fields. Trends and strong demands of the Indian industry such as INDUSTRY 4.0, Automation, Data Management, Connectivity Machine Monitoring demand a global approach, professional and sharp teams to guide customers’ projects.

TOPSOLID India focuses on promoting and supporting TopSolid CAD/CAM/PDM software solutions locally for tool room and manufacturing requirements. TOPSOLID India is led by Sunil Desai and Bhavin Padechia, who bring valuable knowledge of the CAD/CAM/PDM market as founders of DESIGNCELL, specialized in offering manufacturing-based CAD/CAM software services.

With the headquarters in Mumbai and a network of pan-India channel partners, DESIGNCELL has provided services for several leading companies such as TRIVENI TURBINES Limited, SIGMA SURGICAL, TAKAHATA PRECISION, DURIAN INDUSTRIES Limited, PANASONIC, SAFRAN, NAVAL GROUP, etc.

Arnaud de Boisboissel, Business Unit Manager for the Asia-Pacific region in TOPSOLID SAS, says: “I am very committed to be a part of this project with TOPSOLID India. Thanks to the strong dynamism of the Indian CAD/CAM/PDM market and our long-term collaboration with DESIGNCELL’s expert team, we are proud to count more than 1000 TopSolid users in India. Our goal is to improve our local capabilities and service levels to better serve our customers in India while accelerating TopSolid’s growth.”

Sharing their vision, Bhavin Padechia and Sunil Desai, Directors of TOPSOLID India, stated “DESIGNCELL is very proud to take on a new mantle as TOPSOLID India, after an unbroken span of 17 years of collaboration with TOPSOLID SAS. This is a great opportunity for us to increase our market share in India, as well as to contribute to developing the Indian manufacturing sector.”

Please tell us more about your company?
Designcell CAD CAM Solutions provides customised solutions to enrich and enhance design aspects and augment production capabilities. Started a decade ago, the company has been providing CAD/CAM solutions and has a technical prove out centre and machining facility at Vasai, (About 50 km from Mumbai). In addition, services like CMM inspection, Mould and Product design, Fixture design/manufacturing, CNC programming and machining are also being provided by us.

We initially started only selling the software and soon realised that to cater to our customers better we needed to become a complete solution provider. This in turn led us to venture into manufacturing of some of the critical parts for aerospace and space applications, using our own CAD CAM set up, by which we are able to enhance the value proposition for our customers.

What are the other solutions that you provide?
We offer various solutions for the tooling industry that can enhance our customers’ capabilities.

‘TopSolid’ is one of the first products we introduced. It is an integrated design and manufacturing software. This software has been developed by a group of mathematicians from France that makes it much more reliable and versatile for CAD CAM applications.

‘VoluMill’ is a software from USA that offers the most cost effective method of bulk-material removal for all rough milling operations. ‘VoluMill’ is a winner where it matters most ie. cost savings in machining time, less cutter consumption and hence cost and more importantly extended CNC machine life and less power consumption.

‘Tool Quote’ is a software that automates and organizes the tedious task of preparing quotations for toolmakers. The powerful graphic interface in the software allows for faster creation and visualization of tool layouts enabling the tool makers to send quick and reliable responses.

We also deal with magnetic work-holding and clamping devices from ‘Sarda Magnets’ Group. The company is a pioneer in designing and manufacturing of Magnetic work-holding, clamping, separation and lifting magnetic equipments. We provide training to our customers, both onsite and offsite. We have a 24/7 customer service facility including Sundays.

Our aim is to enhance the efficiency and productivity of our customers and continue to introduce them to best-in-class technologies available across the globe.

What do you mean when you say Total Solutions?
It means catering to customer’s demand right from the beginning to the end. If you look at the evolution of any product it begins from quotation, then product design and prototype, tool design thro’ to manufacture with validation at every stage using software and we are with them in all the stages of execution of the project successfully.

What are your views about Indian die mould industry?
India is going to become a manufacturing hub; it’s already in the radar of global manufacturing giants. Once these companies setup their bases in India, there will be an increase in demand for tooling and die mould solutions. Die Mould industry being the back bone of manufacturing, we foresee good times ahead for the tool and die manufacturers.

There are several CAM solution providers in India. How do you plan to compete with them?
Technology is the answer. We have some highly advanced products and we do not just sell products but provide solutions thro’ digital integration. Our philosophy is not selling software but to offer solutions. We handhold our customers in their business growth endeavour and assist them with long term solutions.

Which industry is your most important customer?
Of course Die & Mould. We also see good demand coming from industries like Aerospace, Medical and Energy.

How do you see the future of Indian CAD/CAM industry?
As the demands for automated solutions increase, we see the CAD/CAM industry growing significantly.

Future plans…
We shall keep adding more products to enhance our philosophy of becoming the ‘Total Solution Provider’.

By Nishant Kashyap