Precision verification

Providing high precision engineering services to a range of demanding industry sectors, Flexible Machining Systems (FMS) ensures its machine tools are safe with NC program verification software from CGTech.

Providing high precision engineering services to a range of demanding industry sectors, such as aerospace and defence, medical hardware, pump and food processing industry, systems integration and automation equipment, as well as motorsport, Flexible Machining Systems (FMS) ensures its machine tools are safe with NC program verification software from CGTech. 

Although commercial engineering work is undertaken by FMS, it is predominantly equipped to machine high precision parts and significant capital equipment investments have been made during the past five years, updating machining centres and turning capacity together with inspection. Significantly, having recently gained AS9100 registration, the Horsham-based company is looking to expand its customer base within the aerospace and defence sectors.

The majority of milled components produced by the company are programmed offline and this is supported by a robust IT infrastructure running a number of software programs including Vericut from CGTech.
There are three distinct but entwined software steps for FMS as technical support manager, Peter Smith, explains: “We use SolidWorks CAD and Open Mind as our CAM system to create NC cutting tool paths. These files are transferred to Vericut where we verify the CNC code for the part before performing the machining operation.”

Virtually speaking

Where 3D models are issued, FMS imports the customer data in STEP format and if the company is issued with 2D drawings it always builds a 3D model to work from. The model is passed seamlessly into the CAM system and the NC code is transferred to Vericut. “This ensures we have set up the part correctly in the CAM system, and that we will machine it correctly,” Mr Smith affirms. “We complete a full virtual reality machining operation through Vericut and if there are any mistakes in the program, the software will find them and highlight what exactly is wrong. It will also tell us if we have taken too much material off or if further material needs to be removed.”

CGTech modelled all of the machines for FMS, providing a virtual representation of every machining centre. As some of the 3-axis vertical machining centres can be fitted with a fourth axis rotary unit these have also been modelled to cover every production scenario.

The company builds the manufacturing process from the CAD system and gathers all the data needed into the software. Every cutter and tool holder used by the company is held in a database with around 4,000 combined variations which can be selected in the CAM system. The tooling data can then be transferred into Vericut. All the datum points are also taken across and issued as part of the machine set-up procedure. Post processor proving

FMS has been using solid modelling for over 10 years and Vericut for around five years. As the components produced by FMS have become more complex so the need to prove that the job is right when it leaves the CAM office has evolved. “With components becoming more intricate, we rely on Vericut to prove that we have done things correctly. It's very easy to overlook potential collision situations but Vericut will pick them up every time. In fact, the software is so well thought of that one of our aerospace customers insists that all parts go through Vericut – and we're monitored and audited on this requirement,” says Mr Smith.

Machining complex parts was the reason for a recent investment in a Mazak Variaxis 5-axis machining centre. “The multi axis machine can perform five sided machining operations and often we can finish a part in a single set-up using special fixturing and snap tags,” Mr Smith explains. “We installed the CAM system to support the 5-axis machine tool, and had to have the post processor written for the machine. To prove the post processor, we run it through Vericut and if an error was identified it could be corrected as the software allows you to see exactly what is happening. This worked fantastically because all the problems with the post processor were found straight away.” 

The virtues of verification

One of Mr Smith's responsibilities is making the company more efficient by getting the most out of the machine tools. As far as he is concerned multi-axis machines are the way ahead, machining parts in fewer set ups and operations. He confirms: “If you are using multi-axis machining techniques, Vericut is crucial. It minimises the risk of having a collision – you see any accidental crashes on screen so the machine tool is protected. It is much easier to correct things virtually in the CAM system than face the problems associated with an actual collision.”

No milling programs are manually edited at FMS and any changes are made in the CAM system and re-processed by Vericut to confirm the changes are correct to machine. “We are eliminating as many errors as possible up front,” says Mr Smith. “It's much more efficient for a business to run a verification process and Vericut is the best one available. I would not want to do any programming without Vericut – the CAM system offers verification but it does not check the G code of the actual program. Vericut is driven by the actual NC program so every motion is a response to the driving code and the software will act exactly as the machine will, which makes a significant difference and provides real peace of mind.”

CGTech
www.cgtech.co.uk
 

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