A UK injection mould tool specialist has recently invested in a high-speed milling machine and a high-performance milling machine to increase capacity and overall manufacturing flexibility.

Buckinghamshire-based injection mould tool specialist - Precision Moulds and Tools (PM and T) - has recently invested in a high-speed milling machine (HSM) and a high-performance milling machine (HPM) from AgieCharmilles GF.

The vertical machining centres - a Mikron HSM 800 and a Mikron VCP 800W Duro - have been installed (September 2006) at the company’s 10,000ft2, purpose-built facility in Aylesbury, UK - and provide PM and T with a significant increase in machining capacity and capability as well as improving the company’s overall manufacturing flexibility.

PM and T, established in 1991 by joint managing directors Michael Rush and Paul Newton - and now employing 20 people in the UK - is a market-leading design and manufacturer of complex, high-precision mould tools.

The company has an international reputation for the quality and the sophistication of its tooling solutions (single through to multi-impression) and has a global customer base (US, Far East, Europe, etc) covering a diverse range of industry sectors - medical devices, electronics, white goods, cosmetics, etc * Total solutions - PM and T provides total systems solutions to its customers.

This does not just include the manufacture of complex single and multi-cavity production precision tooling - but also involves working in consultation with customers to develop and design mould tool concepts and prototypes - and providing pre-production testing and sampling services.

The company also has comprehensive mould tool modification and repair capabilities.

This ‘concept through to completion’ approach helps differentiate PM and T from the competition - it also helps explain the company’s continuing growth and success.

Said Rush: “The days when tool makers just ‘made’ things are over.

Customers not only expect (and demand) high-quality, reduced lead times and cost competitiveness from their tooling supplier - they are also looking, in many instances, to work in collaboration with them - sharing expertise, shortening design-to-manufacture processes and lead times - and minimising risk.” This pragmatic and strategic approach to business is evident across all of PM and T’s operations.

* New technology - forward-looking and forward-thinking companies make prudent and timely investments in new technology - and PM and T is a case in point.

Already equipped with state-of-the-art CNC machine tool technology that includes suites of EDM machines (both wire and sink) located in the company’s designated EDM manufacturing cells - PM and T has now invested in Mikron advanced milling technology.

Saidl Newton: “The 2 new Mikron machines were selected for specific (and different) machining applications and operations.

The HSM 800 is a 3-axis High-Speed (HSM) milling machine.

It is being used to hard machine (steel) mould inserts that are often characterised by their intricate forms and micro features.

The machine is also used to manufacture copper electrodes for our spark erosion machines.” The HSM 800 supplied has a high-speed 36,000 rev/min High Torque spindle 20Nm (HSK 50E) and can achieve surface finishes of 0.2 micron Ra and accuracies of +/-6 micron (ISO 230 standard).

The machine’s speed, accuracy and surface finish have resulted in less reliance on EDM spark erosion machining (often a slower process), higher productivity and the elimination of time spent polishing the moulds.

The VCP 800W Duro is also a 3-axis machining centre and is being used on larger mould tools for roughing out operations - where the emphasis is on accurate high volumetric removal.

The machine has a 20,000 rev/min spindle (HSK 63A), 30 position automatic tool changer and rigid work table (900 x 600mm).

Both machines feature the powerful Heidenhain iTNC 530 control plus SMART technology software for improved process reliability and performance (Intelligent Thermal Compensation - ITC; Advanced Process System - APS) and laser tool measurement and workpiece probes - both fitted as options.

As well as both machines fitting PM and T’s requirements - the after-sales service provided by Agie Charmilles was also important in the purchase decision.

Said Rush: “We have a long relationship with AgieCharmilles GF (owing to our Charmilles wire EDM machines) - and value the after-sales services that are provided.”.

http://www.manufacturingtalk.com/news/agi/agi147.html

Jean Michel Vallet has built his engineering workshop by making precision components on CNC machines for mostly local companies, but always with one eye on his long-held dream of building a race car.

In the early 1970s, Vallet was quick to realise the potential of CNC, investing in the first of many numerically controlled machines.

In the late 1990s, the time came to move to new premises; and it was the ideal opportunity to streamline the company’s workshop.

‘When we built this new factory, we had something like seven different makes of CNC machine tools,’ said Vallet.

‘Running the factory was complicated and inefficient.

‘For the sake of productivity, we had to standardise.’ In 1998, Vallet took a trip to the Paris machine tool show where, where he came across Haas CNC machine tools.

‘We found the best machines for our growing company,’ he added.

‘All Haas machines have the same control, which means if you can program one, you can program all of them.

‘Plus, they offer lots of torque, which is ideal because we often use large diameter end mills on stainless steel.’ He was also impressed with the Haas fourth-axis capabilities.

The company now owns several Haas machines, including a VF-9 vertical machining centre.

Vallet began by supplying a local company making machines for bottling plants.

Today, the company’s bread-and-butter work, the work which will pay for Vallet to pursue his motor racing dream, is mainly making parts for companies building food packaging and processing machines, plus some special and secretive aerospace projects.

‘We make scale models of new and prototype aircraft, which are used for wind tunnel testing and are full of sensors measuring airflow and aerodynamic forces,’ he said.

‘We also make five-axis parts for our aerospace customers, which are actually comparatively straight forward to machine.

‘The trickiest parts we make are for the food processing industry, machined from special stainless steels.

‘These parts often have very tight tolerances, which is a challenge because we have to find ways of making them at the price the customer wants to pay.

‘It’s demanding work, which we’re able to do because we use accurate but relatively low-cost machine tools.’ In Vallet’s busy workshop is a line of Haas machines including eight CNC vertical machining centres and five CNC turning centres.

One, a Haas VF-1, runs 24 hours a day using a Kuka robot arm to change parts.

An adjacent PC, using software designed personally by Vallet, controls the robot separately.

PCs interconnect all the machining stations, allowing managers to keep tight control of planning and scheduling.

The factory runs three shifts and 24 hours a day; 10 Haas machines running through the night with just five operators on duty.

‘My aim is to create an entire racing car from just six solid blocks of aluminium, in 70 hours, using only four tools,’ said Vallet.

Big blocks of aluminium, he admits, but just six, from which he intends to machine all of the major and supporting structural components, including the chassis, suspension, mounting brackets, and so on.

No castings, no extrusions, just solid parts.

‘We’ll buy-in brakes, glass, wheels, that sort of thing, we’ll make the body from glass fibre and we’ll use an Alfa Romeo V6 engine, giving 340HP,’ he added.

‘But otherwise, we’ll make it here, on one Haas machine, in less than a week of running two shifts a day.’.

http://www.manufacturingtalk.com/news/has/has151.html

October’s EMO show in Milan, which will bring together the globe’s best manufacturers of CNC lathes and milling machines, will welcome several more heavy hitters in the industry, a British company has revealed.

Ward CNC, which is the sole reseller of many leading brands in the world of precision engineering, announced that its affiliate organisations Hartford, Hankook, Soraluce, Union and Hyundai-Kia will all have space at the get-together.

Hyundai-Kia in particular will be showing a diverse range of its products - nine in all - with turning centres, milling machines and vertical systems hopefully proving the company can offer “highly productive, highly flexible and very cost-effective” solutions.

Hartford will focus on its five-axis vertical machining centres while Hankook will promote its flagship machine, the VTB-160E ram-type vertical boring and turning machine that has a maximum turning diameter and height of 2,000 mm by 1,400 mm, making it suited to larger projects.

Ward CNC has 100 years of experience and reputation in the supply of new CNCmachine tools as well as machine servicing and laser calibration services.

If you’re searching for CNC turning centres compare 1000s here on MTD.

http://www.machinetooldirect.co.uk/machine-tool-news/

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Hankook, Hartford, Hyundai-Kia, Soraluce and Union will all be present at the Milan EMO from 5-10 October to promote examples from their ranges of machine tools, which are available from Ward CNC.

Hankook’s display will focus on the VTB-160E ram-type vertical boring and turning machine that has a maximum turning diameter and height of 2,000mm and 1,400mm respectively, a vertical travel of cross rail of 750mm, and a table of 1,600mm diameter capable of 0.7 to 280rev/min.

Hartford will have several vertical machining centres on view, such as the 5VM-60RT five-axis moving column model, the HEP-3150AP double column, the HCMC-15AG and PRO-1000 AP open-fronted units, and the MVP-10AP plug-and-play machine.

The construction of the Power Centre Pro-1000 is based on a cast-iron frame with hardened and ground box slideways.

The machine has a table of 1,150mm x 600mm that is capable of accommodating workpieces weighing 700kg, and X, Y and Z travels of 1,000mm x 600mm x 510/630mm.

As standard, rapid traverse rate in all axes is 20m/min, the 7.5/10kW spindle produces speeds of 40 to 8,000revs/min (pulley-style; 6,000revs/min geared) and the machine is supplied with a 20-tool (optional 24) automatic toolchanger.

Controlled via the Hartrol-Fanuc AI100/0iMC CNC, a major feature of the control technology is the Hartrol advanced functionality programming routines available as standard.

This offers a series of easy-to-use cycles designed to simplify and speed up programming times and reduce downtime, along with other useful setting and maintenance functions.

The routines embrace, for example, workpiece datum setting using edge setter, manual tool setting using calibrated setting block, tool magazine tracking (for arm-type ATC), tool logging and spindle load monitor, as well as full M Code listings and a comprehensive set of special canned cycles.

A batch of nine Hyundai-Kia machines will be displayed: the SKT700LM turning centre, KH1000 and HS500 horizontal machining centres, SKT-V80RM vertical turning/milling machine, SKT180TTSY multi-tasking twin-spindle turning centre, Hi-V560M/5A vertical machining centre, SKT2100SY Y axis multi-tasking turning centre, SKT2500MTS multi-tasking mill/turn centre, and the SKT-F160/2SP twin-spindle turning centre.

The Hyundai-Kia SKT MTS multi-tasking centre will demonstrate that it can achieve highly productive, highly flexible and cost-effective single set-up mill/turn applications from a four-axis unit.

The SKT 2500 MTS features a 18.5kW, 8,000revs/min, high-torque B-axis milling head and the 4,500revs/min sub-spindle with full C-axis capability (that complements the 30kW main spindle), which, with ‘kissing spindle’ design, enables synchronised part exchange at 30m/min rapid traverse.

The machine’s credentials for flexibility are based around the milling head that has +1,200 rotation with 0.0010 indexing through a heavy-duty, dual-lead worm gear and servo motor.

The head has the added advantage of 250mm Y-axis stroke for off-centre feature machining and a Z-axis stroke of 1,100mm servicing both main and sub-spindles.

The milling head slide (that also accommodates standard lathe tooling) also carries a 22-tool magazine (optionally 43 or 65) that provides a tool change time of just 1.5s and chip-to-chip time of 5s.

The maximum tool size is 95mm diameter, which can be extended to 104mm when adjacent pockets are empty.

With a bar capacity of 76mm, a 10in chuck size and options of programmable tailstock, the SKT MTS has a maximum turning diameter and length of 500mm and 1,100mm respectively, while the swing over the bed is 780mm.

The machine uses Fanuc 18i-TB as the control system.

It offers high power in a heavy-duty single cast bed construction with rigid box guideways.

If the optional, fully programmable 110mm diameter quill tailstock is specified, automatic clamp and unclamp is incorporated.

Soraluce will have trio of machines on display: the FX-R-20000 floor-type, the SP-10000 fixed table, travelling column model and the bed-type TA-25-A.

With a vertical (Y axis) stroke of 6,500mm, a cross travel (Z axis) of 1,900mm and a longitudinal traverse (X axis) of 20,000mm, the FX-R-20000’s 3,000mm x 3,000mm table can accommodate 40-tonne workpieces.

The machine has feed and rapid traverse rates in X, Y and Z axes of 10-10,000mm/min and 20,000mm/min respectively.

The machine’s ‘multi-purpose single set-up’ heavy machining through to high-quality surface finishing tagline is endorsed by its 120-tool ATC, and the use of the automatically interchangeable 37kW, 4,000revs/min orthogonal head, which can position in 1deg by 1deg increments, complementing the 46kW, 2,500revs/min, 37kW fixed boring head that can position in 2.5deg increments, and the 4,000revs/min fixed horizontal head, as well as a wide range of optional CNC tables.

Control is via the Heidenhain iTNC 530.

Union will be promoting the PR 200/250 - a boring mill designed for simultaneous rough and ultra-precision finish machining of large workpieces.

Up to 8m high and weighing 250 tonnes, it is equipped with a spindle diameter of 250mm and a main drive motor rated at 130kW that produces torque up to 17,000Nm.

Rapid feed rates are up to 25m/min.

The ability to combine roughing and finishing is made possible by the use of hydrostatic guideways in the main X, Y and Z axes.

Hydrostatic guideways utilise a permanent oil-film between guideway surfaces to eliminate mechanical wear.

They also permit high chip removal rates due to the resulting high damping effects.

http://www.manufacturingtalk.com/news/war/war207.html

Modern tooling technology enhanced the output on elderly machines for one company, while converting to single-point thread milling is paying dividends elsewhere. Machinery explainsThetford-based Instrument Machining Service specialises in the manufacture of components for the aerospace, motorsport and precision components sectors, mainly for the after-market and repair markets, using a variety of conventional and CNC machine tools.

Many of the parts manufactured are small in size, such as nuts, bolts, washers, spring guides and bushes. Due to the applications they are used in, they have to be manufactured to the same strict aerospace specifications and tight tolerancing as what might be considered more glamorous parts.

Image: By employing modern tooling technology on its existing machines, Instrument Machining Service was better placed to make investment decisions when considering new equipment

Over the past few years, and under the guidance of managing director Glen Parfett and assistant manager Dean Smith, the 15-employee business has undertaken a radical review of its manufacturing processes. The result is a dramatic improvement in productivity and workflow. The company has looked at all aspects of its business, which has seen a greater involvement of all of the staff, a programme of training that has ensured a greater degree of multi-skilling on the shopfloor and investment in machine tools. However, one of the biggest catalysts for change has been a review of its cutting tool application.

DEMAND PROMPTS ACTION
As part of this review, Instrument Machining Service has made full use of its relationship with cutting tool supplier WNT (UK) (0800 073 2073), as the application of modern cutting tool techniques has been central to many of the improvements made. “About three years ago, industry was moving forward at a very fast pace and, to be honest, we were finding it difficult to keep up with the increase in demand,” says Mr Smith. “We were faced with a choice of replacing a number of our existing machine tools in order to increase productivity, a route that would have been prohibitive, due to the cost.” That assumption was based on the belief that its existing machine tools could not fully exploit modern cutting tools. But, with the support of WNT (UK), the company did investigate tooling as a first course of action.

“Utilising the machines we already had by investing in new tooling, and the increases in feeds and speeds that we achieved, made a significant impact on improving our manufacturing capacity, workflow and delivery performance before we even had to consider new machine tool investment,” says Mr Parfett. “The added bonus was that eliminating many operations by using the next generation of tooling – such as WNT’s HPC milling cutters, the multi-function Eco-cut tools and driven toolholders – opened up many more machining possibilities, reduced non-cutting and work in progress time, as well as eliminating many second operations, reducing the overall number of tools and generating additional savings.”

By attacking the problem this way round, Instrument Machining Service was then in a much better position to assess just which machines needed to be replaced and the subsequent capital expenditure was much more focused.
And the cutting techniques that the company tested on its older machine tools are now being put to even better use on its new ones.

An example of how this co-operation worked at Instrument Machining Service is the use of WNT (UK)’s HPC solid carbide end mills on a machine that is 20 years old. The machine has a maximum 4000 rpm/min spindle, and the prospect of running the latest in solid carbide cutting tool technology was a daunting one. However, with support from Adam Cross, WNT (UK)’s technical sales engineer for the area, this machine is now achieving feed rates of 0.75 m/min, while improving surface finish, maintaining tolerance and only taking a single pass. The company has subsequently maintained and gained business.

For example, a low-volume part that was proving difficult to machine, and as a result was sub-contracted by IMS, was brought back in-house when volumes increased and the sub-contractor demanded an increase per part. With tooling technology revisited, and by working with WNT (UK) and Mr Cross, the cycle time on these parts was reduced by 66 per cent. This one-time problem component is now a profitable part for the business.

To keep this cutting tool technology under control, Instrument Machining Service has now taken the next step and installed a WNT TooloMat tool vending system.

Elsewhere, a leading Scotland-based supplier of high technology sub-assemblies for use in the oil industry has made significant savings by utilising helical interpolation thread milling with single point tooling supplied by Horn, via Scottish distributor Peter Campbell Sales.

On one job alone, the switch from multi-flute inserts to a Horn (01425 481800) Supermini Type 105-derived special tool to produce 0.25 inch UN threads saves £1,000s per year, due to longer tool life and reduced insert cost. In addition, superior thread quality, as defined by improved parallelism and cleaner thread profiles, has virtually eliminated rework requirements.

PART OF THE WHOLE
This application was one of a wider programme of conversion to single point thread milling. The end user company operates in a sector where quality is critical, machining substantial components from materials, such as 420 grade stainless, 4140 stainless and Inconel 718, using a variety of high quality CNC machine tools. These alloys represent a machining challenge in any circumstance. However, the problem is often compounded by difficulties relating to accessing the location of the designated feature.

In the case of the 0.25 inch thread instanced above, the feature is machined in the front face of a shoulder situated about 200 mm from the front face of the component. This demands use of a lengthy extension bar to present the threading tool to the bore, which is itself counterbored at the entrance.

Instrument Machining Service’s production engineer comments: “With the multi-flute tool that we used previously, there was a cumulative rigidity problem, because of the way that the tool interfaced with the holder. This led to quite rapid wear of the tool, which compromised the quality of the thread.”

The solution, introduced by Horn, utilises a purpose-built long length toolholder. This is produced to the maximum cross section that can still clear the spigot and access the bore. The bar is tapered at the ‘business end’ to a short tool holder section. The Type 105 thread milling insert clamps directly to the holder, using a single central screw. Torque is transmitted by precision machined matching interfaces on the tool holder nose and insert back designed so that the assembly acts as a solid entity.

The tool assembly is more rigid, while the cutting forces developed by the single point cutter are lower than those for a multi-flute cutter, reducing the risk of vibration.

“The Horn set-up provides a more consistent high quality thread, which eliminates the need for rework. Moreover, tooling costs are significantly lower,” says the sub-contractor.

http://www.machinery.co.uk/article/19576/Tooling-challenges-met.aspx

An expert in CNC machining is promoting the efficiency of its latest electrical discharge machining (EDM) offerings.

GF AgieCharmilles is outlining its Econowatt systems, highlighting its functional abilities in reducing energy bills and contributing to a better environmental outlook.

The high-performance FI CCS range of EDM machines provided by the organisation are all fitted with the Econowatt system, which makes it possible for operational costs to be dramatically cut and create the greenest CNCmachine tools of their kind on the market.

AgieCharmilles explained that rough cutting operations, with everything taken into account including generator, injection pump and filtration system power, is approximately 8kW.

Sleep mode on the FI CCS models is dramatically low, with power consumption coming in at just 0.8kW, making it a great option for those hoping to cut costs and be more environmentally-friendly.

Last week, AgieCharmilles launched a new range of spark erosion machines - the FORM 200 and FORM 300 - built to support all-night automation.

If you’re searching for milling machines compare 1000s here on MTD.

http://www.machinetooldirect.co.uk/machine-tool-news/

CNC-machining-firm-highlights-eco-drive-2009-8-19.asp

Featuring welded, one-piece frame, PPEC Press Brakes provide capacities from 80 tons, 2 m to 220 tons, 4.2 m. Backgauge fingers allow gauging to 39.4 in. and also serve as material supports. To ensure optimal control of bending process, microprocessor technology is linked to servo-controlled hydraulics and electronics. All models are equipped with CADMAN® Lite control, which offers 2D graphic programming with automatic collision detection and direct angle or Quick Bend programming.

Press Brakes feature 4-7 CNC controlled axes.

LVD Strippit Introduces New PPEC Series of Mid-Range Press Brakes

Akron, NY — LVD Strippit introduces a new line of PPEC press brakes designed as a mid-range bending solution to offer a balanced mix of performance and value for less challenging forming applications.

LVD Strippit’s new PPEC press brakes, including PPEC-6 and PPEC-7 models, provide capacities from 80 tons, 2 meters up to 220 tons, 4.2 meters with four to seven CNC controlled axes, depending upon machine model.

PPEC press brakes provide a rugged, welded one-piece frame machined without repositioning guaranteeing machine precision. Hydraulic cylinders are machined from a solid steel billet. Pistons are steel forgings, precision ground and micropolished for years of trouble-free service.

Microprocessor Technology is linked to servo-controlled state-of-the-art hydraulics and electronics to ensure perfect control of the bending process and optimum precision. Double bed referenced encoders are connected to the bed in such a way that deformation of the side frames during bending does not influence the positioning accuracy of 0,01 mm of the upper beam (Y1-Y2).

The PPEC’s two-axis backgauge allows depth (X-axis) and height (R-axis) positioning of the two standard backgauge fingers. PPEC-6 and PPEC-7 models offer the additional flexibility of Z1 and Z2 motorized backgauge movement. The standard PPEC backgauge fingers allow gauging to 39.4″ (1000 mm) and also serve as material supports. PPEC-4 and PPEC-5 models can be fitted with an additional third finger support, which is ideally suited to the bending of channels.

A V-axis crowning system fitted to PPEC-5 and PPEC-7 models ensures parallel and consistent bending results on longer bending length over the different tonnage levels.
All new PPEC press brakes are equipped with LVD Strippit’s new CADMAN® Lite control. Based on the same easy-to-use platform as the full-featured CADMAN® Touch control, CADMAN Lite offers a number of the same key features, including 2D graphic programming with automatic collision detection, direct angle or Quick Bend programming, and connection with LVD Strippit’s CADMAN-B offline programming software.

ABOUT LVD

The LVD Group is a leading manufacturer of a comprehensive range of sheet metal/plate working machine tools and software solutions, including laser cutting systems, punch presses, press brakes, guillotine shears and mid-level automation systems, integrated and supported by its CADMAN® PC-based Windows® compatible software.

http://news.thomasnet.com/fullstory/564631

For the manufacture of turned parts up to 7mm diameter, an easy to operate CNC turning centre precisely machines small components to a guaranteed precision of +/-2 micron.

At the UK’s MACH 2008 machine tool exhibition, Tornos will be giving the Micro 7 its UK exhibition debut.

The new Micro 7 guarantees precision of +/-2 micron whilst demonstrating excellent flexibility, productivity and operator simplicity, said Tornos.

Designed for the manufacture of turned parts up to 7mm diameter, the Micro 7 is ideally suited to the precise small component and electronics sectors.

With a maximum workpiece length of 60mm and a spindle and counter spindle speed of 20,000 rev/min, Tornos is offering a highly productive machine proven to outperform the cam-type machines that have dominated this small component sector.

Tornos told manufacturingtalk.com that to enhance processing times the Micro 7 combines its high speed spindles with simultaneous machining in front and back operation modes.

* Flexibility - with flexibility instilled in every aspect of the Micro 7, this remarkable machine can hold up to 20 tools on a 5 + 2 axes configuration (with C-axis), explained Tornos.

The Micro 7 can work with a wide range of tool holders and equipment suited to the exacting needs of every user.

Meeting the productivity, accuracy and flexibility demands of the modern machine shop, the tools on the Micro 7 work independently for flexible manufacture.

* Programming choice - for ease of use and customer simplicity, Tornos is launching this machine with the option of the renowned Tornos TB-Deco programming system or the industry standard ISO system driven by a Fanuc Series 32i control.

All these elements are built upon a strong and rigid construction that delivers the productivity and accuracy benefits associated with the Tornos family of turning centres.

For further information on the Tornos Micro 7 that will be available from the second quarter of 2008 or any alternate turning centres in the Tornos range, please come and visit us at MACH 2008, said Tornos.

* Tornos Technologies at MACH 2008, NEC, Birmingham.

UK, April 21-25, Hall 5, Stand 5575.

http://www.manufacturingtalk.com/news/toa/toa188.html

Used for programming CNC mills, lathes, WireEDMs, turn-mill centers, and Swiss-type lathes, PartMaker v2010 includes features for optimized visualization of thread whirling, 2½-axis milling functionality, and programming of complex parts. Direct interface option to PowerMILL is offered for all complex 5-axis machining strategies supported by PowerMILL, including blade and blisk machining, as well as sophisticated 3-axis strategies. Various other milling strategies are also included.

New PartMaker Version for 5-Axis Simultaneous Milling for Multi-Axis Lathes to be Unveiled at EMO 2009 in Milan

Latest PartMaker version featuring 5-axis simultaneous machining for multi-axis lathes, more powerful milling functionality and a host of other improvements will debut at EMO 2009 in Milan.

Fort Washington, PA - PartMaker Inc., a division of Delcam Plc, will unveil its latest version of PartMaker Software for programming CNC Mills, Lathes, WireEDMs, Turn-Mill Centers and Swiss-type lathes at EMO 2009 October 5 - 10, 2009 in Milan, Italy. Major highlights of this newest release, PartMaker Version 2010, include the ability to perform 5-axis simultaneous milling on multi-axis lathes, more powerful milling functionality and the ability to better visualize thread whirling. A host of additional productivity, user-driven enhancements will also be featured in PartMaker Version 2010.

PartMaker will be exhibited in the booth of its parent company Delcam Plc at EMO 2009.
PartMaker Version 2010 is slated for release in the fourth quarter of 2009.

“PartMaker Version 2010 provides the technology PartMaker users will need to stay on cutting edge of manufacturing and stay ahead of the competition by employing the most advanced milling strategies available on the market today,” says PartMaker Inc. President Hanan Fishman. “With the ability to program simultaneous 5-axis milling operations on multi-axis lathes and more powerful 2 ½ axis milling functionality among other improvements, PartMaker users will be able to program even more complex parts than ever before. These new milling capabilities, along with enhancements such as improved thread whirling visualization, will be especially beneficial to a large segment of PartMaker users involved in the manufacture of medical devices.”

“While 5-axis simultaneous milling is still new in the arena of Swiss-type lathes, multi-axis lathes with 5-axis simultaneous milling capability are becoming more commonplace in small parts manufacturing. PartMaker Version 2010 positions PartMaker users to take advantage of the growing complexity of milling on multi-tasking machines. PartMaker Version 2010 represents a quantum leap forward for users and potential users of PartMaker technology,” comments Fishman.

The 5-axis simultaneous milling functionality in PartMaker Version 2010 is based on robust, well-proven technology used in PowerMILL, Delcam’s world leading specialist NC CAM software for the manufacture of complex shapes. Sharing the vast technology pool of its parent company Delcam, the largest CAM-centric developer in the industry, has allowed the PartMaker development team to deliver more advanced manufacturing technology to the market place faster.

5-Axis Simultaneous Milling for Multi-Axis Lathes
PartMaker Version 2010 features an optional module to perform simultaneous 5-axis swarf milling on multi-axis lathes. Swarf machining is a technique that allows side cutting with an endmill while proceeding along the surface of a part, such as the sidewalls of a tapered rib. Swarf machining can be used for profiling the edge of components using the side of the tool to remove material. The benefits of 5-axis simultaneous swarf machining over traditional 3-axis milling strategies include significantly reduced machining time and improved surface finish. Employing swarfing can allow parts to be machined complete in a single set-up by allowing for more advanced de-burring techniques thus eliminating time consuming and laborious additional finishing.

The new swarfing functionality in PartMaker lets users take advantage of B-axis lathes with 5-axis simultaneous machining functionality. PartMaker’s 5-axis swarf milling is powerful, yet easy to use, allowing the user to apply this complex machining technique in an intuitive manner.

PartMaker and PowerMILL Integration
For all complex 5-axis machining strategies currently supported by PowerMILL, including blade and blisk machining, as well as for highly sophisticated 3-axis strategies, PartMaker Version 2010 will feature the option for a direct interface to PowerMILL. PowerMILL tool paths can be imported directly into PartMaker Version 2010, manipulated and synchronized on PartMaker’s Process Table, simulated and post processed directly from the PartMaker working environment. This integrated solution of two market leading technologies assures users they will never be limited in their ability to program and optimize parts in the most efficient and powerful way possible.

More Powerful Milling Strategies
PartMaker Version 2010 features a number of more advanced 2 ½ axis milling routines not available in previous PartMaker versions including a variety of High Speed Machining Strategies, Trochoidal Milling, Rest Area Machining, Face Milling and a more powerful Pocketing strategy among others. These additional milling strategies are also based on PowerMILL technology and have been adapted to work inside of PartMaker in an efficient and easy-to-use manner.

Improved Thread Whirling Programming and Simulation
PartMaker Version 2010 includes an improved facility for automating the programming and simulation of thread whirling, a programming technique often used in the programming of “bone screw” threads as well as other specialty threads commonly found on threaded surgical implants. The popularity of thread whirling attachments on Swiss-type lathes have grown substantially in recent years because of the dual benefit this technique offers manufacturers making threaded parts. Specifically, thread whirling allows threaded products to be produced faster because this technique only requires a single pass, where as traditional multi-pass threading routines require multiple passes to achieve the same result. Additionally, with the rigidity afforded by a sliding-headstock Swiss-lathe, thread whirling can also provide higher and more repeatable precision.

PartMaker Version 2010 includes specially developed algorithms and user interface to automate the programming of this unique manufacturing technique. Additionally, PartMaker’s 3D simulation fully simulates machining with a thread whirling attachment as these attachments can generally be quite large inside the working envelope of a machine and thus provide additional risk of collision during machining.

Additional Productivity Enhancements
PartMaker Version 2010 includes a number of user requested productivity enhancements. Among these improvements are: enhanced grooving functionality, powerful and flexible threading capability, improved solids-based programming and additional CAD functionality. Additionally, 2D tool path selection has been improved from previous versions. The new automated tool path selection techniques in PartMaker Version 2010 will provide users a significant productivity improvement by measurably speeding up programming time. Space ball support has also been added in PartMaker Version 2010. Additionally, a number improvements to the software’s Tool Database have been made in Version 2010.

More on PartMaker
PartMaker is a Knowledge Based Machining system, allowing it to provide a substantial gain in programming efficiency by remembering the tools, material and process information necessary to machine individual part features. It thus relieves the user from reentering the same features information for subsequent parts. It also improves productivity by placing the emphasis on tool management functions.

PartMaker pioneered the field of CAM software for Turn-Mills and Swiss-type lathes with its patented Visual Programming Approach for programming multi-axis lathes with live tooling. It assures quicker learning and easier use. It makes an extensive use of pictures to help the user describe tools, part features and machining data. Synchronization of tools working on multiple spindles is achieved by a few mouse clicks.

PartMaker Inc. is a subsidiary of Delcam Plc, the world’s leading developer and supplier of complete CAD/CAM software solutions. Delcam Plc is publicly traded on the AIM exchange in London. While PartMaker is sold direct in North America by PartMaker Inc. PartMaker is sold overseas through a network of sales partner offices operating in over 120 countries.

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