Shop-floor programming cuts toolmaker's costs

WorkNC is helping Pure Medium, based in Nuneaton, UK, to rapidly deliver patterns and prototype tooling to its customers in the wind turbine, aerospace, defence and automotive markets.

Keith Oldham, managing director of Pure Medium, installed WorkNC on the shop floor to maximise productivity and eliminate the delays associated with office-based programming.

Oldham said: 'We get model data in IGES, Step and native Catia format.

'Generally it is fully surfaced, so we only need to add split lines or run offs in WorkNC prior to adding the toolpaths.

WorkNC can interrogate and modify the surface model, cutting sections, checking draft angles, patching holes and measuring dimensions.

Previously, this was performed on a separate CAD system, but now it can all be done on the shop floor.

The machine operators understand exactly what extra geometry is required to enable them to add the toolpaths and, because they can carry it out themselves, there is no delay and no possibility of communication error.

By making the best use of the skills of its machine operators, the company can optimise its machining processes, save the cost of an office-based CAD/CAM specialist and utilise the time that the operators have while the machine is running, in the most effective way.

Two operators use WorkNC at Pure Medium and found the system easy to learn.

Oldham added: 'Reliable handling of imported CAD data, the tools to modify and repair surfaces and the software's automatic toolpaths are a big help.

'Users only have to be computer literate to operate WorkNC.

'It was much easier to learn than the other systems we considered, as it has been designed to suit a machine operator's way of working.

Collision checking and avoidance are important features for Pure Medium.

This is especially true for the 3+2 axis machining it uses on complex jobs.

Oldham added: '3+2 machining is simple to program, we just change the axis or add a view.

'We find the collision avoidance particularly useful on steel moulds, where we need to use shorter cutters for rigidity.

'The software adds loops in the corners, which eliminates squealing and the subsequent damage to the tool and job.

The company has experienced increased tool life since the installation of WorkNC.

It has also saved money by making use of available cutters, working with suppliers to test and implement new types of tool and by taking advantage of any special offers.

Because WorkNC is used on the shop floor, the operators have the flexibility and knowledge to optimise machining processes and get the most out of their cutters, making significant savings in tooling costs.

The automatic toolpaths in WorkNC make programming straightforward and reliable.

The company uses Global Roughing and 3D Planar Finishing for the majority of its work, even though each job is different.

The stock and rest models keep the tool engaged with the material, avoiding air cutting, while trochoidal tool movements eliminate shock or excessive tool loading.

About 95 per cent of the prototypes and moulds produced by Pure Medium go through WorkNC, so its performance is an essential part of the company's success.

Oldham added: 'We have absolute confidence in the results produced by WorkNC.

'It gives us fast collision and tool-breakage-free machining and produces consistent and reliable toolpaths.

'Furthermore, its simple operation enables us to get significant time and cost savings from shop-floor programming, maximising our use of resources.

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