Offset-aware programming of spindle transfers and bar pulls helps manufacturers drive multi-channel CNC machinery with confidence.

New computer-aided-manufacturing (CAM) technology has been introduced by ESPRIT CAM, part of Hexagon’s Manufacturing Intelligence division that provides manufacturers with the control and flexibility needed to use multi-spindle and multi-channel computer-numerical-control (CNC) machinery for the machining of long parts. More accurate simulation of spindle transfers and bar pulls enables manufacturers to exploit multi-tasking machinery with high productivity program creation of error-free toolpaths.

Machining long parts, such as shafts and axles, is challenging because they require that the workpiece is supported throughout to maintain cutting speed and surface quality. The main and sub spindles must be synchronised to ensure that cutting can be performed while both spindles hold the workpiece for maximum support. Bars are also frequently repositioned in incremental steps to keep workpieces rigid, as well as to account for limited bed length. Because the repeat repositioning of the bar presents a collision risk, it benefits machinists if they are supplied with NC code that tracks machine motion for greater flexibility and readability at the machine control.

Without the ability to track machine motion, a significant amount of time is spent hand-editing NC code and troubleshooting programs before production begins using complex multi-tasking scenarios. ESPRIT TNG CAM software now automatically tracks the location of work offsets regardless of part position by enabling programmers to define the offset and offset translations, or the points at which offset changes occur. In addition to enabling precise simulation, this eliminates the need for custom settings or calculations to the machine post to ensure that parts are machined accurately and makes it possible to program a greater number of complex machining scenarios without error.

“ESPRIT TNG is ‘the next generation’ CAM because it provides an exact digital replica of every facet of the machining environment to help manufacturers use the world’s most sophisticated, cutting-edge machine tools with confidence,” said Olivier Thenoz, ESPRIT principal product manager. “The ability to accurately track parts throughout complex operations means that users can make the most of the combined power of software and machinery for advanced multi-tasking, and that they have the freedom and flexibility needed to machine exactly the way they want to.”

ESPRIT TNG now also enables manufacturers to perform face-milling operations with a unique “roll-in” lead-in strategy recommended by Sandvik Coromant to improve surface quality, reduce cycle time, and extend tool life. This lead-in technique positions the cutter for ideal thick-to-thin chip formation, which indicates that the insert engages the material deeply enough at entry to make a significant cut before exiting smoothly to reduce vibration and ensure consistent, high-quality surface finish. In addition to being less damaging to cutter inserts, this strategy eliminates the need to manually calculate face-milling stepovers during the programming process, which automatically ensures a consistent and even surface across the entire workpiece.

The new release also offers productivity benefits for 3-axis operations. Toolpath creation is now 20 times faster, meaning that toolpath that once took 30 minutes to generate can now be calculated in about two minutes. Furthermore, a new 3-axis toolpath can now be created in ESPRIT TNG from an existing operation without recalculating the entire toolpath. Areas in collision can be trimmed from toolpath generated for use with short cutting tools, or re-machining operations can be created with a long tool to cut only areas that cannot be reached with the shorter tool.

Simplify the part-programming process, significantly increase part accuracy, and greatly reduce the length and complexity of your G-code program with ESPRIT.

Complete Machine Control
ESPRIT provides a universal EDM contouring cycle to machine any contoured mold, die, core, cavity, shape or profile. This versatile machining cycle supports any number of straight or tapered rough and skim cuts while optimizing wire cutting paths. Strategies for all styles of EDM machining such as punch, die, multi-cavity parts, and unattended machining are included. Between cuts ESPRIT automatically handles all the necessary wire-cut and wire-thread instructions, and part-handling functions of the machine: flushing, tank fill, and tank drain.

Advanced Tapering
Easily program the complex tapers common to mold components, forming dies, and cutting tools with the advanced conics capability of ESPRIT’s contour cycle. When cutting a radius during tapering, built-in advanced conics allows you to alternate between cylindrical constant radius corners and conical constant taper corners. ESPRIT also provides independent programmable upper and lower radius control. While tapering into sharp corners, ESPRIT offers you the flexibility to maintain sharp corners top and bottom or machine a blended radius on the secondary plane.

4-axis Synchronized Machining
Quickly program parts with extremely complex tapers or completely independent freeform shapes, top and bottom, with ESPRIT’s XY (lower), UV (upper) 4-axis contouring cycle. Select any two three-dimensional profiles and the 4-axis cutting process is automatically synchronized; you can add an unlimited number of additional synchronization lines. ESPRIT adds tabs automatically and creates skim cuts for unattended machining. Get 4-axis programming for any geometric shape with any number of elements: 3D, non-planar, UV and XY profiles, and non-planar fixturing.

Efficient No-Core Cutting
Handling slugs efficiently during EDM machining becomes more difficult with decreasing workpiece size. ESPRIT provides a special EDM no-core pocket machining cycle to erode away all the material inside a given cavity without creating a slug. With no-core cutting, a start hole is drilled into the workpiece and ESPRIT recognizes and automatically machines only the slug, preventing wire breakage and minimizing machining time.

Factory-Certified Solutions
ESPRIT’s machine-specific EDM KnowledgeBase provides you with a full range of cutting features, automation, and factory-certified post processors to maximize performance. Readily access each EDM manufacturer’s unique cutting technology and methodologies through machine-specific technology pages.

E-manufacturing Technology, an event to showcase unique integrated manufacturing solutions has been organised during the Global Industrial Expo scheduled from November 21-24, 2014 at Auto Cluster Exhibition Centre, Pune. With an aim to impact the precision machining industry with a special emphasis on the Die &Plastic mould industry, the event will witness like-minded players presenting as a team – machine tools, CAM software, tooling, tool inspection/ presetter, cutting tool manufacturer, component inspection/ probing, tool/ die steel manufacturer and component holding systems among others. It is a first-of-its-kind initiative where metalworking giants have decided to come together to demonstrate the value of advance manufacturing technologies.

The partner companies will integrate their technologies to demonstrate the importance of automation. Companies that will be showcasing their best solutions are MAZAK (machine tool), Speroni (tool presetter), SCHUNK (work holding), DIJET (cutting tools), ESPRIT (CAM) and Big Dishowa (tool holders).

Ashok Raj, Mentor, E-manufacturing Technology says, “Pune is one of the biggest hubs for die and mould manufacturers in India. However, much of this business is slowly but surely migrating to the overseas market of Taiwan, Thailand and China, primarily due to cost and quality considerations resulting from the high degree of manual intervention (matching / lapping) in the manufacturing process by Indian suppliers. Through this platform we desire to integrate these partners together and demonstrate how this business can become highly competitive through improvement in quality, productivity and cost reduction.”

Talking about the awareness of latest technology S Ravishankar, Deputy Managing Director, Yamazaki Mazak India Pvt Ltd says, “There should be awareness or knowledge as to what is the right technology and the purpose the technology will serve. Awareness can only be developed by witnessing the technology exhibitions, attending seminars etc. Today, with the advent of internet, the distance is no more a concern and information can be brought to individual desks. Hence, it is much easier to spread awareness where there is interest.”

The event is planned in such a way that it will benefit both the operator and management. Management can learn about the importance of the automated technologies, while operators can learn best shop floor practises.

Ravi Moolya, General Manager & Country Head, Speroni India Pvt Ltd adds, “At times we see that companies have good machines but compromise in tooling systems, etc. This not only affects the quality of the product but also their business. Through this seminar we would like to spread awareness among the professionals that how using the best technologies can help them achieve better productivity thus reducing the cycle time. We are also inviting people working on the shop floor to talk about tips and tricks of various machining activities.”

India is slowly losing out to other nations due to lack of a cohesive support from the government, inadequate awareness of latest technologies and lack of technological know-how. In order to raise awareness, MFGTechupdate.com has been selected as the official media and marketing partner for the event. The premium machine tool media house will help the event to reach out to the potential audience. Apart from online media, Efficient Manufacturing, leading machine tool monthly magazine is also on board as an official print media partner.  The event is said to address some major issues that the Indian companies have been facing.

See you at E-manufacturing Technology, Global Industrial Expo!!!