To achieve high-tolerance machined parts for the fighter plane, the company is “strongly encouraging” use of Siemens Sinumerik Volumetric Compensation System.

Renee Robbins — Control Engineering, August 11, 2009

In June, Siemens Energy & Automation, Inc. announced that Northrop Grumman Corp. Aerospace Systems is “strongly encouraging” its supply chain to explore the use of Siemens Sinumerik 840D solution line CNC and Sinumerik Volumetric Compensation System (VCS) to achieve high-tolerance machined parts for the F-35 Joint Strike Fighter program.

“Siemens collaboration on the F-35 program began in early 2002 with a CNC technology symposium in Fort Worth attended by Lockheed Martin, Northrop Grumman and BAe Systems,” said Tim Shafer, director of Siemens Aerospace Center of Competence in Mason, OH. “Since that meeting, the program partners have applied the advanced features of the 840D to solve many of their complex machining challenges.”

To find the right equipment to produce these high-tolerance machined parts, Northrop Grumman and its technology partners invested in developing and testing advanced technologies that would enable a step-change in machine tool accuracy. Northrop Grumman’s testing revealed that a number of key machine tool attributes are necessary to achieve the required high-tolerance machined parts. These include robust machine design, machine tool repeatability, machine tool responsiveness, environmental temperature stability, and stable machine foundation.

The Sinumerik 840D sl CNC, from Siemens Motion Control business unit, can provide real-time internal compensation for geometric and feedback errors of a five-axis machine tool. In operation, The 840D sl’s VCS solution factors all the machine kinematics of its various axes of motion, as well as pitch, yaw and roll. This corrects the tool center point and orientation, resulting in a substantial improvement in volumetric accuracy for fork-head style five-axis machines.

At the end of August 2009, Siemens is expected to make a significant announcement about improvements in CNC programming capabililities.Visit www.crackthegcode.com for a sneak preview.

See also: Machine control: Long bed CNC gantry mills achieve unprecedented accuracy
A Siemens Volumetric Compensation System and proprietary temperature compensation system combine with laser calibration to achieve +/- 0.003 in. accuracies.

http://www.controleng.com/article/327268-Northrop_Grumman_recommends_

Siemens_CNC_technologies_for_use_by_F_35_supply_chain.php

Mills CNC has announced that order intake for the first half of 2009 exceeded £14 million.Exclusive distributor of Doosan machine tools into the UK and Ireland, this achievement follows the company’s best-ever first quarter results (January – March), when the company reported orders in excess of £7 million.

“The latest sales results show that, despite current economic conditions, the strength, popularity and value for money of the Doosan and Mills brands are second to none,” said Nick Frampton, Mills CNC managing director.

“In the first 6 months of this year, we increased our market share across the board and, probably the most illuminating statistic we have to hand of this is that 33 per cent of all machine tool orders achieved during January to June were to new customers.”

The managing director also highlighted that the company has carried over a record order book - £8 million - into the second half of the year.

Further analysis of the company’s performance reveal that approaching two-thirds of all CNC lathes (chuck size 12″ or above) sold in the UK in the first half of 2009 were Doosan lathes; and a quarter of machining centres (verticals and horizontals) sold during the same period were also Doosan machines – all supplied by Mills.

As far as the remainder of 2009 is concerned, and also looking forward to 2010 and beyond, there is confidence that the sales performance achieved to date can be replicated - and improved upon - in the months to come, it is said.

“New Doosan machines and models will be launched by Mills into the UK in the near future – and these will help us move into new markets and consolidate our strong position on others,” Mr Frampton underlined.

‘”These new machines include the new range of vertical machines with Heidenhain controls (available since July 09), and a new range of Doosan 5-axis machining centres, which will be available towards the end of the Year.

“We’re confident that these new technology developments combined with the drive and commitment of our people will help Mills achieve even greater success in the future.”

http://www.machinery.co.uk/article/19512/Mills-CNC-orders-exceed-14-million-for-the-half-year.aspx

Despite the recession, one firm continues to defy the economic climate.

The economic woes of the UK may be affecting a number of companies, yet one is going from strength to strength, achieving “outstanding business results” by its own admission.

GB Precision, a company which utilises turning machines and CNC lathes, has two months of its financial year still to run yet has had its best year ever.

Managing director of the CNC machining firm Paul Turner said the year has been particularly hectic up to now, with many organisations demanding the manufacturing of “complex tooling” for the particularly high-precision packaging caps and closures market.

He continued: “In order to cope with this increased workload we have expanded the factory, nearly doubling the available floor area, as well as making significant investments in state-of-the-art equipment.”

Established in Birmingham in 1968 by Gerald Turner, the company’s facilities provide 8,000 sq ft of workshops and it has recently been extended to provide room for new equipment and increased demand.

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

CNC-machining-firm-is-flying-high-2009-8-13.asp

A Siemens Volumetric Compensation System and proprietary temperature compensation system combine with laser calibration to achieve +/- 0.003 in. accuracies.

Coast Composites Inc., part of the UK-based Hampson Industries Plc, is a major supplier of Invar tooling, as well as resin transfer molds and mandrels used in the composite lay-up and manufacture of today’s advanced flight-critical aerospace structures. Coast also builds tooling for the construction of end products like satellite reflectors used in the telecom and military markets. On the large, long bed CNC gantry mills used at its main facility in Irvine, CA, the company is achieving unprecedented accuracy on even the longest wing skins as a result of two complementary technologies.

Coast Composites runs many grades of aluminum, plus A36, P20, stainless, monolithic graphite, carbon fiber composites and other materials, in addition to Invar 36 and 42. The largest CNC mill at Coast is a German-built Handtmann five-axis machine that uses twin Siemens Sinumerik 840D numerical controls and accommodates structures to 22 ft. wide x 75 ft. long x 84 in. high. The Siemens Volumetric Compensation System (VCS) acts in tandem with a proprietary temperature compensation system devised and implemented by Coast engineers. Combining these technologies with ongoing laser calibration, Coast achieves and maintains accuracies to +/- 0.003 inches on its longest runs.

The showcase machine tool at the Coast facility in Irvine is a Handtmann five-axis CNC long bed gantry mill, capable of running structures to 22′ W x 75′ L x 84″ H, utilizing a powerful 80 hp, 60 kw spindle up to 15,000 rpm. The 40,000 lb. bridge can move at 2200 ipm. Using the Siemens Volumetric Compensation System (VCS) and its own proprietary temperature compensation system, Coast achieves a better than +/- .0003″ accuracy on wing skin tooling and other structures that often occupy the entire machine bed.

Jerry Anthony, Coast Composites founder and “director of best practices,” says, “We knew the Siemens Volumetric Compensation System had substantial merit for our operation when it was first introduced to us, precisely because of the workpiece sizes we run and the corresponding thermal growth during machining, even on Invar tools. We had developed our temperature compensation system to adjust the go-to points from the control for real-time temperature on the machine and the workpiece. The data covered all aspects of our machining, from material composition to acceleration/deceleration mapping and the temperature variations over the largest pieces and longest machine cycles we had performed.”

Compensating for temp variations
Anthony says the key point of interface for such a system is within the algorithms of the CNC, acting to compensate the signal before sending commands to the motors and drives for adaptive action on the machine tool. In a typical long machining cycle on the very large parts produced at Coast, temperature variations in the workpiece material combine with the naturally occurring thermal expansion in the machine tool to create serious dimensional issues. This is true for whatever material is being run on the machine, even the Invar high nickel-iron alloy used extensively at Coast for producing composite lay-up tooling, fiber tape mandrels and other structures.
While Invar has an extremely low coefficient of thermal expansion, the length of the machine cycle invariably (the word from which Invar got its name) results in sufficient thermal movement of the machine, which adversely affects the tool tip position.

Operator uses one of the twin Siemens Sinumerik 840D CNC stations to control the movements on the Handtmann gantry mill. The two CNC units are linked to communicate seamlessly in parallel, thus allowing a single operator to run this massive machine safely and efficiently.

In operation, Siemens VCS factors all the machine kinematics of its various axes of motion, as well as pitch, yaw and roll, to precisely adjust the orientation of the tool tip to the workpiece. The true workpiece coordinates, rather than the programmed tool tip position, determine the actual cutting path. In conjunction with the highly advanced Siemens cutter path contouring, this compensation process results in a smoother finish on the part surface and a very high degree of machining accuracy.
In the Coast application, they have further enhanced this process by combining its proprietary temperature compensation system with the VCS inside the CNC to produce a highly accurate cutting path that takes into account the thermal expansion rates for the particular material being run as well as the machine itself.
While other companies in the industry typically run such machine tools in a completely air-conditioned environment, Coast Composites has devised its temperature compensation system to overcome these variables in ambient

factory conditions and still maintain an accuracy that often exceeds the customer specification, regardless of the material being machined. The standard NC program assumes a 20 ºC (68 ºF) normal operating condition-normal for a coordinate measuring machine [CMM]. The CNC incorporates the Coast temperature compensation system software, while the DNC runs the Valisys software, reading off the Renishaw touch probe data from the workpiece surface. Thus, the temperature compensation is within the machine control-resulting in real-time adjustments to the machine movement and an overall improved surface finish with superior accuracy, according to Anthony.
The Siemens CNC is also used to complete the on-machine inspection of the workpiece. “We have used laser tracking in tandem with our Valisys inspection software for some time now, having had a Siemens CNC engineer in Elk Grove Village, IL write the machine tool inspection interface software for us,” says Anthony. “In this way, we were and are now still able to use the power of the CNC to run real-time inspections and data analyses. [These] have been extremely useful as an in-process inspection system for any tool manufactured by Coast.”

An operator monitors a high-temperature 1800ºF oven, used for stress relieving and full annealing of weldments and other structures. The oven workspace measures 76′ L x 26′ W x 15.5′ H.

Anthony says that the Coast system “essentially turns every machine tool here into its own CMM.” The laser tracker is now used primarily for final checking, as the in-process monitoring produces what he says “might be the highest-accuracy machining standard in the aerospace industry.” He says Coast has “run enough material types and enough cycles to develop an impressive data base of averages over time. Our algorithms are the key and, when married to the Siemens power onboard the CNC, result in the old adage that says the whole really is greater than the sum of the parts.”

Invar tooling and mandrels produced at Coast Composites are used for the production of various commercial and military aircraft.

On the massive Handtmann five-axis gantry mill, application engineering and training assistance were provided to Coast Composites by the machine tool builder’s local representative, Bryan Wilson of BD Technology, as well as personnel from the Siemens Aerospace Center of Competence. “The relationship between the Siemens Aerospace Center of Competence and Coast Composites began seven years ago and has progressed to a true partnership, as the two companies have worked together consistently, merging advanced theoretical technologies with experiential knowledge,” says Anthony.

http://www.controleng.com/article/327270-Machine_control_Long_bed_CNC_gantry_mills_achieve_unprecedented_accuracy.php

Under the terms of a licensing agreement Lantek has granted TekSoft distribution rights for Lantek sheet metal software through TekSoft’s international VAR network.

TekSoft and Lantek have signed a software licensing and distribution agreement.

Under the terms of this agreement, Lantek grants TekSoft distribution rights for Lantek sheet metal software through TekSoft’s international VAR network.

The software for punching, laser, waterjet, plasma and oxyfuel machines will be marketed under the FABWorks name.

TekSoft, a leading provider of CAD/CAM applications since 1981, develops and markets CAMWorks, which is available for machining centers, turning, mill/turn, multiaxis and wire EDM applications.

CAMWorks is a SolidWorks Certified Gold CAM Product that provides state-of-the-art machining capabilities seamlessly integrated into SolidWorks 3D mechanical design software.

FABWorks also provides an integrated interface between the SolidWorks design environment and the FABWorks machining environment.

Parts that are designed in SolidWorks can be automatically unfolded and transferred directly to FABWorks for machining.

The benefits of this agreement were clear to both companies and negotiations were concluded quickly.

“TekSoft has over 20 years of experience in developing and selling CAD/CAM software through a large VAR network.

When they decided to expand their product range to include sheet metal software, they investigated the fabrication systems available in the market and talked to our competitors,” stated Alberto Martinez, Lantek’s managing director.

“In addition to Lantek’s best-in-class CAD/CAM software, our international reputation as a leading software company in the sheet metal industry made their decision an easy one.” According to Mike Coleman, President and CEO of TekSoft, “We seek out the best-in-class solutions, we negotiate and we license.

This allows us to provide a full suite of established and proven CAM solutions while offering ongoing enhancements.

The agreement with Lantek enables us to quickly offer our customers a product that is at the forefront of the sheet metal software industry.” Coleman also stated that TekSoft is offering FABWorks at a significant discount to its existing ProCAM fabrication customers to encourage them to make the transition.

* About TekSoft - TekSoft develops and markets CAMWorks, which is available for machining centers, turning, mill/turn, multiaxis and wire EDM applications and ProCAM, a stand-alone CAD/CAM product.

TekSoft sells its products through 140 resellers in 40 countries and has an installed base of over 33,000 licenses.

TekSoft is a subsidiary of Geometric Software Solutions Co .

(GSSL), a leading PLM services provider with over 20 years of experience in CAD/CAM/CAE, PDM and MPM.

Based in Mumbai, India, GSSL has business development headquarters in Merrimack, NH, USA, and sales offices in Germany, Singapore and Japan.

GSSL is publicly traded on the Bombay Stock Exchange and the National Stock Exchange in India.

* About Lantek - Lantek develops and sells CAD/CAM software for the sheet metal industry.

Lantek CAD/CAM software product range includes punching and cutting software for oxyfuel, plasma, laser and waterjet machines as well as software to drive press brakes, tube cutting machines and production management software.

Lantek is one of the leading software companies in the sheet metal industry with distributors worldwide and branch offices in Spain, France, Germany, Italy, UK, USA, Japan, South Korea, India, and Czech Republic.

Lantek is a recognized provider of sheet metal software with more than 5,400 customers in 76 different countries.

http://www.manufacturingtalk.com/news/tfy/tfy106.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

Adjustable or fixed pattern multiple spindle drilling heads with the correct adapters at a very affordable price with short delivery times can be easily mated to CNC machine tools.

Adjustable or fixed pattern multiple spindle drilling heads with the correct adapters at a very affordable price with short delivery times can be easily mated to CNC machine tools.

CNC machines are popular in many operations.

In most cases, these machines have sufficient horsepower to handle the extra load of drilling multiple holes simultaneously.

Multiple spindle heads from AutoDrill are now easily mated to these machines.

AutoDrill can provide adjustable or fixed pattern heads with the correct adapters at a very affordable price with short delivery times.

Custom multi-drill heads and adapters made for your pattern and equipment can generally be shipped in three to four weeks.

In addition, information for conventional drilling machines such as drill presses (drilling machines), mill-drills, vertical mills and tapping machines have been accumulated by AutoDrill.

With this database of information, they can provide a prompt quotation for both the multiple spindle drilling head and the adapter.

http://www.manufacturingtalk.com/news/aod/aod109.html

CNC controls vendor NUM has introduced a 3D simulation package that combines workpiece simulation with collision monitoring and other features.
The CAE software allows machine builders to offer new generations of optimistion tools with their machines. Designated True 3D, the software tool is a general-purpose version of NUM’s 3D simulator for multi-axis grinding.
True 3D is said to be one of the first commercial CNC software simulation tools to combine both workpiece simulation and collision monitoring facilities.

It allows machinery users to virtually prototype and optimise the entire machine production process, to yield significant gains including improved machine productivity, reduced tool wear, and faster project completion.

The simulator visualises the tools, the machine’s kinematic properties and the workpiece blank as 3D volumes. Material volume is removed from the workpiece as the tool moves along the machining track according to the CNC program, while the same volume is continuously subtracted from the workpiece blank.

The 3D simulation calculates the entire process chain of a machine tool, from the ISO standard CNC program and its CNC processing, to the machining process.

http://www.manmonthly.com.au/Article/Advanced-3D-CNC-simulation/492934.aspx