Feature Based Computer Aided Machining (CAM)

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Feature Based Computer Aided Machining (CAM)

• GMP Final Report Presentation

Team Members Lyle Newman, Steven Ronald, Stefan
Lyn Shue, Yau Chan
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Computer Aided Manufacturing - CAM

• Introduced in 1980s
• Computer Aided Manufacturing (CAM) is the process
  of using software to generate the G-code
• G-code is used to control CNC machine tools
• G-code often uses a .step file extension.
• Information stored in the G-code is used to
  control the coordinates of the cutting tool,
  spindle speed, feed rate
• This is accomplished by
• Constructing databases pertaining to machining
  parameters and making the information available
  to the user as effectively as possible
• Creating the an efficient way for the user to
  define the tool path

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Feature Based CAM

• Introduced in the 1995 FeatureMILL2.5D (3D by
  1997)
• Distinguishing specific features of a CAD file as
  being able to be created by a process of
  machining operation.
• Once the feature is identified, the most
  effective method to machine that feature is
  determined by the software.
• Computes which combination of processes and
  parameters is optimal
• User validates the selected processes and
  parameters
• User can make modifications based on the shops
  capabilities and his/her knowledge of
  manufacturing.
• This results in much shorter turnaround time and
  allows for very quick cost estimates
• No matter how good the software is experience is
  invaluable

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Applicable Machine Tools - Any CNC Process

• Turning/Boring
• Milling
• Mill/turning
• EDM
• ECM
• Grinding

• Water Jet Cutting
• Laser Cutting
• Plasma Cutting
• Drilling
• Reaming
• Multi-task simultaneous machining

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Feature Based CAD/CAM

• Traditional CAD software defines geometry
  defining lines, points, splines, extrusion,
  revolve ..
• To define a pocket Sketch the 2D profile of the
  pocket and then extrude/subtract to the desired
  depth. Then add fillets and a chamfer.
• Software packages FeatureCAM use features to
  define the CAD geometry
• To define a pocket Tell the software to add a
  pocket. It will then prompt the user for the
  required info such as location, width, depth,
  chamfer, fillet radius.
• This is quicker and eliminates error of the CAM
  software incorrectly identifying the features.

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Feature Based CAM Database

• FB CAM software comes equipped with large
  databases of machining parameters such as
• Speeds and Feeds for different operations,
  materials and cutting tools, machine tool
  capabilities, machining time..
• GibbsCAM incorporates knowledge capture into
  their software
• Databases can be personalized with data specific
  to their shops capabilities and past history.
• Customized templates can be stored for a series
  of operations that are used frequently.

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Quick Terms

• CAM
• Computer Aided Manufacturing
• PLM
• Product Lifecycle Management
• QA
• Quality Assurance
• ROI
• Return on Investment
• OEM
• Original Equipment Manufacturer

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Advantages

• C.A.M
• Feature-Based / Traditional
• reduce the costs of producing goods.
• enables manufactures to make quick alterations to
  the product design.
• ability to manage simple tasks such as the
  re-ordering of parts.
• ability to sense errors, send messages to their
  human operators and await further instructions.

• Classic
• Traditional Tools / Machines
• none

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Disadvantages

• CAM
• Feature Based / Traditional
• Setting up the infrastructure can be extremely
  expensive.
• requires not only the computer numerical
  controlled machine tools themselves but also an
  extensive suite of CAD/CAM software and hardware.
• There is no universally used standard for the
  code itself. (G-Code)
• Design Conversion Issues
• CAD to CAM software
• 3-D CAD designs to G-Code

• Classic
• Traditional Tools / Machines
• More skilled labor
• Inconsistent Quality
• Lower Production Numbers

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Direction and Innovation

• Current Processes and Practices
• Ease of Use
• out-of-the-box capabilities providing Process
  Wizards, templates, libraries, machine tool kits,
  automated feature based machining and job
  function specific tailorable user interfaces.
• Manufacturing Complexity
• CAM systems support the full range of machine
  tools including turning, 5 axis machining and
  wire EDM.
• Integration with PLM and the Extended Enterprise
• Todays competitive and successful companies have
  used PLM to integrate manufacturing with
  enterprise operations from concept through field
  support of the finished product.

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Direction and Innovation

• Future Processes and Practices
• Consolidation
• Second Order Benefits
• Safeguarding design intent by elimination of
  geometry redrawing.
• Eliminating errors by verifying CNC tools paths
  to reduce rework or scrap.
• Minimizing machine-to-machine transfers to cut
  delivery times and simplify operations.
• Minimizing setups to reduce process variation.
• Integrating inspection and QA to avoid delays
  and recalls.
• Simulating processes to generate accurate time
  estimates and avoid collisions.
• Increasing worker productivity.
• Optimizing the use of equipment to eliminate
  bottlenecks.

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Feature-Based CAM Software

• Large variety of brands available
• Most are built specific for a niche market
• Several large products have emerged as industry
  leaders
• Esprit
• GibbsCAM
• FeatureCAM
• Mastercam

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Capabilities

• Increased accuracy to design parameters
• Quicker project lifecycle times
• simplify the machining and designing process for
  CNC machining
• Ability to make minor and major changes
• Flexible (Mold Machining, Production Milling,
  Production Turning, Multi-Axis Milling, Sheet
  metal manufacturing, Specialized Mfg)

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Limitations

• High initial investment cost per seat
• 5k to 15k license cost optional 10 IT support
  fee
• Advanced training necessary
• Online exercises
• In-person conferences seminars
• Experience of user a critical factor
• Blindly exporting code is dangerous

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• Used on machine tools in over 15,000 shops across
  the globe, and is available in more than 15
  languages from over 200 resellers.
• 2-5 axis Milling
• 2 - 22 axis turning
• 2 - 5 axis wire EDM
• Multitasking mill-turn machining
• B-axis machine tools
• High-speed 3- and 5-axis machining

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• Base package's capabilities can be extended
  through the addition of integrated modules.
• Customizable
• Easy to use/short training time
• Tool, mold, and die
• Production milling
• Production turning
• Wire EDM

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• Feature-Based Technology to Streamline
  Programming
• Large support team
• Data Translation
• Feature Recognition
• Turn and turn/mill
• 2D milling
• 5 Axis 3D milling
• Wire EDM

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Mastercam X3

• Industry Standard with 136,000 installed seats,
  double closest competitor
• Flexible and powerful
• Large online community for advice, tips, and
  tricks
• Mill
• Lathe
• Wire
• Routing

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Mastercam X3
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Hawk Industries Inc.

• Before using CAM during 1970s
• Program long-hand with high speed editor
• Binary system store information on tape, which
  inserted into a machine
• Data was stored on floppy disk
• Also used telex machine
• All required experienced background

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Advantages

• Use 5min to acquire preliminary cost estimate
• Reduced part programming times by 30 and helped
  the company to triple its output.
• Reduced machining time for its alloy steel
  components overall by 80.
• Save up to two hours a day on a rig that costs
  150,000-300,000 a day to operate.
• Improvement in part consistency and a saving of
  more than 35 in assembly time for the more than
  500 different parts that make up the devices.

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Built Rite Tool Die Inc

• 2000/1999 Before
• Hand Programming Milling with 3 Axis Mill
• Generated through x, y points by hand, then input
  into controls
• Tracing scaled

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Advantages

• More features with EDM
• Using MasterCAM, more detail per electrode
• Transition gradual quick payoff
• Reduce turnaround time
• Necessity to be competitive these days

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Conclusion

• CAM generated data improves business
  effectiveness. It reduces time and resources
  needed for each job, assures the job will be done
  right, on time and using the best practices.
• CAM is essential for a manufacturing shop to be
  productive and successful Mike Russo, Hawk
  Industries Manufacturing Consultant

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Q A