Product category:
Software, off-line programming, CAM, for metal cutting machine tools
News Release from: Pathtrace Engineering Systems | Subject: EdgeCAM off-line programming software
Edited by the Manufacturingtalk Editorial
Team on 24 June 2003
Weeks long production times reduced to
days
Off-line programming software has revolutionised the machining of complex duplexer units, reducing production times from the normally expected several weeks cycle to just a few days.
Pathtrace's EdgeCAM off-line programming software has revolutionised the machining of complex duplexer units produced by Aerial Facilities, a market leader in the manufacture of development components for the telecoms sector As a result, the company has been able to reduce production times from the normally expected several weeks cycle to just a few days
This article was originally published on Manufacturingtalk on 9 Jan 2003 at 8.00am (UK)
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Outlining the success of the new system, CNC programmer, Ken Davis, who was largely responsible for the decision to buy EdgeCAM based on his previous experience with the system, says: "We recently programmed a complicated duplexer which was machined from a solid block of aluminium.
It had 16 pockets 40mm by 40mm by 30mm deep and a wall thickness of just 4mm.
It also had hollow circular posts in the centre of each pocket and some 60 drilled and tapped holes.
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To which workshop team leader Steve Cyster adds: "We were able to program the part off-line with EdgeCAM from start to finish in well under five hours." In addition, the company found there were even more benefits than simpler, faster programming because the EdgeCAM-developed machining strategy ensured the part was completed in under 2.1/2 hours.
And, due to this improvement in manufacture - which included a much higher confidence of what would happen on the shopfloor - Aerial was able to reduce its production time on the project from several weeks to just a few days.
It was the need to speed-up the manufacture of development components such as cell enhancers and boosters that led the Chesham (Bucks) firm to invest in new CNC machine tools and EdgeCAM.
As a result, its recently expanded development workshop has seen lead times slashed by a staggering 75 per cent on its programme for telecoms boosters and delivery times have also been shortened on a wide range of radio frequency (RF) components.
Now with the enhanced capabilities, the workshop is able to take on certain types of production work, as it is so much more competitive - which also helps recoup payback on the investment.
Formed in 1972, Aerial Facilities designs and manufactures equipment for the enhancement and interference-free operation of radio communications systems.
Its products broadly fall into two categories: active devices, such as cell enhancers that improve network coverage; and passive devices, which include filter and multi-coupling systems that enable more efficient use of the radio spectrum and single antenna working.
Being able to custom design products and systems to solve particular RF problems has been the forte of it's success, and its engineers tend to partner customers to develop solutions that are both practical and economic, such as, installations in the Dartford Tunnel in Kent and at Heathrow Airport.
While most of the 200 staff are engaged in the design, development and assembly of communication devices, 70 per cent of Aerial Facilities' workshop tasks are focused on development cell enhancers and a wide range of booster units known as duplexers and triplexers.
Each prototype has to be thoroughly tested to ensure optimised performance for the environment in which it will have to function, which can be as diverse as international airports, underground railway systems, tunnels and all manner of buildings and industrial units.
Because many of the new components then have to be modified or fine-tuned prior to production, in order to progressively improve their RF performance, they are frequently returned to the workshop for additional machining and adjustment.
Only when a component has been fully proven and tested in the field will it be passed to a subcontractor for manufacture in production quantities.
Development work is based on the 2.1/2D machining of aluminium cell enhancers and duplexer or triplexer booster systems.
These rectangular or square units have a matrix of profiled pockets, of which some are required on two faces with a myriad of drilled and tapped holes and various sealing grooves.
As programming is now totally carried out using EdgeCAM, the system is DNC linked to the three CNC machines in the workshop.
Prior to the Pathtrace system being installed, in December 2001, programming was either performed manually or through an ageing CAM system.
As Ken Davis reflects: "From experience, I knew EdgeCAM was the easiest and best way to upgrade our programming because the software combines power and performance with ease of use.
It is certainly cost-effective, very quick to set-up and run and, most importantly, Pathtrace operates such a good support desk.
I was not impressed with the previous CAM system which was slow and used a variety of different windows.
As the department is under constant pressure to push through development machining, in my view EdgeCAM provided the perfect solution." Booster components range in size from 75mm by 50mm by 38mm thick up to 550mm by 435mm by 140mm thick and batch sizes average around 10.
While general machining tolerances tend to be around 0.1mm, surface finish requirements are high at 8 microns Ra.
Manufactured from a solid aluminium billet, a typical duplexer unit involves machining between 12 or 16 pockets measuring some 40mm square by 30mm deep.
These are closely spaced with a wall thickness of 4mm and most have a hollow circular post in the centre.
Some units are fitted with replaceable copper units which are then machined as a raised cylinder.
It is the height of the walls and slot sections that are highly crucial to the performance of the RF booster and it is these features which often have to be modified following development testing.
In addition to milling, up to 80 drilled and tapped holes of M 2.5 or M 3 are required and on the top face while various countersunk holes are required in the back face of the unit.
This means between four and six different set-ups can be required.
Maximum productivity can now be gained from programming because the new machines enable more efficient cutting using special solid carbide high-helix slot drills and endmills.
As Ken Davis concluded: "On one particularly urgent job, I programmed a smaller duplexer unit from scratch and we machined eight parts in less than two days.
We could never come anywhere near that level of efficiency or machine with such confidence with our old CAM system," he said.
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