Five-axis CAM avoids machining collisions

When a UK aerospace subcontractor acquired a new DMG 5-axis machining centre it wanted to protect its investment with 5-axis software that guaranteed collision avoidance.

When Midland Aerospace of Nottingham invested in a 5-axis DMG machining centre in 2005, the company immediately turned to Open Mind and its hyperMILL CAD/CAM software to support the new investment.

As Midland Aerospace managing director Eamon Lyons commented: "When we acquired our new DMG machine we wanted to protect our investment with 5-axis software that guaranteed collision avoidance - Open Mind was the only company that could meet our needs." The progressive aerospace manufacturer purchased a DMG EVO70 5-axis machining centre to enable the company to produce complex components for its customer base that includes Airbus, GKN, BAE Systems, Raytheon, Aerostructures Hamble (Smiths Aerospace) and Contour.

The introduction of the new 5-axis machining centre immediately made the company's current software all but redundant.

The 3/4-axis package had no collision avoidance and it struggled to cope with the increasingly complex components manufactured on the new machine.

As a preferred supplier to DMG, the company was advised to work with Open Mind.

However, like any sensible company Midland Aerospace fully evaluated the market to find the package to meet its exacting needs, involving its two experienced programmers from day one.

Reviewing the available packages, the programmers found competitor products difficult to use and noted that they did not have collision avoidance.

When the two programmers worked with hyperMILL from Open Mind, they immediately noted the ease of use and the reduced programming times that derived from the customer friendly interface.

The selection was easily made!! * Investment builds growth - the new machine and software immediately reaped rewards for Midland Aerospace with the company continually winning business that involved the production of complex 5-axis components from aluminium, titanium and stainless steel.

The increased business has since seen the BSI and EASA (Aerospace Standard) registered company acquire a second DMG, an EVO50 5-axis linear machining centre.

This in turn has seen the company buy a second hyperMILL seat to accompany the machine.

Purchased in July 2006, the increased production of intricate parts has led Midland Aerospace to upgrade from the hyperMILL Pro package to the hyperMILL Expert.

This enhanced version has improved functionality, something that has further reduced programming times for the aerospace company.

As Lyons continued: "We no longer have problem parts.

The capability of the machine and the software now simplifies and enhances the production of all complex components.

When we investigated software packages, hyperMILL not only came out on top for its performance, ease of use, functionality and collision avoidance - it was also the presentation of the company.

The Open Mind staff has built a strong working relationship with us.

This has been based on the support, presentation and the confidence they have instilled in us with regards to the software." The improvements the company has seen since employing the combined technologies of Open Mind and DMG have been staggering.

However, as Lyons stated: "We also use subcontractors and it's quite surprising that the ones using hyperMILL not only deliver on time, but the parts have a superior surface finish." Lyons concluded: "Open Mind and DMG have both been superb.

If we did not invest in this high specification technology we wouldn't have been able to undertake the work that has now become our every day business.

In August we will be taking delivery of our third DMG 5-axis machine (a large DMU 100P) as part of the company's ongoing growth and development into working at the cutting edge within the demanding aerospace industry.".

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