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Product category: Software, off-line programming, CAM, for metal cutting machine tools
News Release from: Pathtrace Engineering Systems | Subject: EdgeCAM computer aided programming
Edited by the Manufacturingtalk Editorial Team on 01 August 2002

Off-line programming ensured mill-turn
success

When a high performance brake specialist installed a mill-turn centre off-line programming helped to bring in-house previous sub-contract components.

When high performance brake specialist Alcon Components of Tamworth installed an Hitachi Seiki HiCELL mill-turn centre the idea was to bring in-house previous sub-contract components Due to the complexity and high productive capability of the machine, Alcon's engineers decided to thoroughly research all the off-line programming systems that were available, to ensure they obtained the most effective solution for C and Y-axis combination machining when using driven tooling

The decision to purchase EdgeCAM computer aided programming from Pathtrace of Reading has been rewarded with a claimed 99 per cent confidence factor that any program run directly on the HiCELL will be free of major errors.

In addition, certain programming routines that previously took hours are now produced in well under an hour and previous sub-contract costs have been reduced by half, due to the high technology CAM and machine tool combination.

Alcon Components prides itself on a high-class, fast response philosophy to customer care.

It is a policy that has been very successful, lifting the company to be one of the top three manufacturers of caliper brake systems for race and high performance cars.

Formed by John Moore in 1984 when he was Managing Director of Alexander Controls, Alcon Components supplies brakes, clutches and associated equipment to the motor sport industry in North America, Europe and the Far East.

Its brake systems are used by many top race teams such as those in NASCAR and Formula Renault as well as by leading rally teams, including Skoda, Subaru and Hyundai.

Alcon brakes also feature in several limited edition high performance road cars such as the Brabus Mercedes, the Prodrive Subaru Impreza P1 and Ford Racing Pumas.

When Alcon split from Alexander Controls in 1991 it had just 14 employees.

Today, over 60 people are based at its Tamworth headquarters plus eight in the USA and three on mainland Europe.

Production is totally concentrated in the UK and virtually all components are produced at Tamworth.

John Moore maintains that: "Keeping production in-house rather than sub- contracting gives us maximum control and enables us to quickly deal with any 'panic' requests from customers.

Our philosophy is to provide a fast response, which is not easy when batches can be just a single part.

We spend a lot of effort to reduce lead times and EdgeCAM has proven to be a powerful tool for this." It was the desire for in-house high quality production that led Alcon to invest in the HiCELL.

Previously, parts such as disc bells, master cylinders and brake pistons, which have radially milled and similar features, were sub-contracted.

However, programming such complex multi-axis machined components presents its own problems and this led Alcon to scout for a suitable off-line system.

Programming Manager, Rob Taylor takes up the story, "We thoroughly examined off-line programming systems from all the leading players.

The Pathtrace software was the only one that would give us total support in programming turned components that extensively use C-axis spindle combined with Y-axis turret crossfeed for off-centre feature machining in a single hit cycle.

The bonus was that EdgeCAM came with a built-in post processor for the HiCELL, although EdgeCAM's Code Wizard is able to write post processors for any new CNC equipment." He continues: "It is simple to program with EdgeCAM.

I input the drawing of the part and surround it with the billet or casting material, which then allows me to view it on screen in fully textured solid.

EdgeCAM then automatically calculates the cutter paths and delivers the most efficient program.

For particularly 'nasty' profiles I can call up PathComp that automatically compensates for tool tip radii." He follows on to describe how the program can then be fully simulated and verified on a tool-by-tool basis with any collisions detected.

"This is supported by on-screen viewing as a full solid and at any angle we require.

With this, I can be 99 per cent certain that when I run the program on the HiCELL there will be no major errors," he maintains.

Programs that would have taken hours to produce manually are now prepared with EdgeCAM in a fraction of the time.

Here, Rob Taylor cites a disc bell that took half an hour compared to several hours previously.

Machining times are also shorter thanks to both the HiCELL and EdgeCAM.

One example is a heat barrier insert that fits on the end of a brake piston to act as a heat shield between the hot brake pad and the brake fluid.

It has a series of radial holes on its periphery, has recently been programmed with EdgeCAM and is just about to go into production on the HiCELL at a cost estimated to be half that of the sub-contractor.

While such cost savings are important, it is the fast response through in-house production and EdgeCAM programming at the front end that is the real benefit to Alcon.

John Moore paints a particular scenario: "A part can be drawn up in the morning, Rob Taylor will then program it with EdgeCAM so that it is ready to run by the evening.

Come next morning, the batch has been machined overnight ready to be shipped for heat treatment with delivery to the customer scheduled for the next day.

Such a 48 hour turnaround would never be possible with a sub-contractor," he insists.

"EdgeCAM has also broadened the scope of our design engineering," continues John Moore.

"We can now machine desirable features that we were reluctant to handle before.

EdgeCAM has given us the confidence to tackle virtually any job," he states proudly.

Another feature of EdgeCAM admired by Rob Taylor is radial milling which allows slots and holes to be programmed 'on the flat' after which, the envelope is wrapped around the part's circumference.

This feature was used to such good effect on the heat barrier insert to program the drilling and profile chamfering of the radial holes.

There are several versions of the insert which retain the same basic form but differ in size and number of radial holes.

Here, the PCI parametric programming function in EdgeCAM has proven ideal for rapidly developing family of part type programs.

It enables the 'family' profile to be programmed and a dialogue box created.

Entering the specific geometry into the dialogue box then enables each part program to be created.

Alcon have been using EdgeCAM for some 18 months to which John Moore concludes: "I can't describe our use of EdgeCAM as anything but a cost-effective success.

Driven by Rob Taylor, the HiCELL has proved to be a very versatile machine, fully complemented by the tool path creation from the Pathtrace software.

Together, they are powerful tools that will help as we continue to exploit our full potential in the ever-more competitive motor sport sector and high performance niche car markets.".

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