Read the full story (PDF) - SolidCAM

Neumag, Germany 06/07PRODUCTIVE“ Low Viscosity Oil ” for the Process ChainThe profitable use of stateof-the-artmachining centresrequires a powerfulCAM department.Every CAD/CAM process chain is always onlyas strong as its weakest link. The transformationof conceptual design ideas intomachining technologies is a potential weakpoint. If multisided machining of parts ina single set-up should become a key foreconomic success, experienced machiningspecialists and the superior software toolsare needed. With SolidWorks and SolidCAMNeumag found a 3D CAD/CAM solution thatis both powerful and practical with futurepotential.Neumag relies on SolidCAM forNC programming: The scope ofmachining for some workpiecescomprises 200 to 300 differentmachining operations in a singleset-up. In addition to roughing andsmoothing, there are also a lot ofdrilling and deep drilling operations.Oerlikon Saurer Textile, a division of theSwiss-based Oerlikon corporation, is theworld leader in full-service solutions in textilemachinery and brings together leadingbrands such as Allma, Barmag, Jinsheng,Neumag, Melco, Saurer Embroidery,Schlafhorst, Volkmann and Zinser. Themachines, systems and services cover thecomplete range of textiles manufacturing(with natural and synthetic fibres) and theproduction of nonwovens.For over 55 years Neumag has beeninvolved with systems and equipment in theworldwide synthetic fibre and nonwovensindustry and is viewed as the market andtechnology leader for plants and systemsproducing BCF carpet yarn and syntheticstaple fibres. In nonwovens the branch ofthe Saurer GmbH is also the top supplier onthe market, offering a one-stop shop of completesolutions for all essential processes inthe production of nonwovens.A lot of very precise, but rather complexcomponents are required to build thesesystems, which are for the most part customized.The efficient machining of theseparts is a core competence of NeumagSaurer, where 220 of the 415 employeesin Neumuenster work. The manufacturingspectrum ranges from small parts weighing50 grams up to 10 ton monster workpiecesmeasuring up to 5 x 3 x 2 m³. In additionto steel and pipeline design, Neumag has aversatile and extensive CNC machine parkfor turning and rotary milling, milling in 3,4 and 5 axes as well as cylindrical and flatgrinding. In addition to in-house production,up to 30% of available production capacityis taken by external orders, making Neumagthe place to go for the complete machiningof large and heavy workpieces and weldedparts such as wind mills, engines, generators,gearboxes, chassis, etc.Sometimes involving 200 to 300 differentmachining operations, the scope ofmachining workpieces is so extensive thatavailable centres would work round the clockWWW.SOLIDCAM.COM

For the automatic machining in one set-upthe CNC machining centres require a varietyof precisely preset tools that are immediatelyaccessible.for a week with one clamping. In addition tothe complexity of machining, the ambitiousrange of parts keeps Production SpecialistThorsten Nebbe on the go. “The NC programsbasically contain our historicallydeveloped machining know-how. This is afundamental component for the market successof every company. We now have nearly40,000 tested and optimized NC programsin our archive.” An impressive number!And the question comes up, which CAD/CAM system can master this “diversity” inquantity, quality, time/schedule and is alsoflexible?Neumag Saurer has relied on the SolidWorks3D CAD system for about 5 years. ThorstenNebbe began at Neumag just as the systemwas introduced. Armed with 15 years ofexperience in different NC programmingsystems it became his task to evaluateand introduce a suitable 3D CAM system,which he now supervises as a full-timejob. “We looked at a variety of solutions. Apress release then brought my attention toSolidCAM. The Nortec trade fair in Hamburgtook place shortly after that. And there I hadthe first opportunity for a presentation.”It was so convincing that three SolidCAMlicenses were ordered after a test installationin May 2002.Seven SolidWorks+SolidCAM seats arenow installed at Neumag. Thorsten Nebbe:“A striking argument in favour of SolidCAMwas of course the complete integration inSolidWorks. However, more important tous were the CAM features, the programmingapproach and, above all, the issue ofpostprocessors.”Neumag has currently installed 24 differentCNC centres, e.g. OKUMA, Hermle, Burkhardt+ Weber, Mazak, Deckel Maho, SHW, beingsupplied with NC programs via a DNC network.The range of control units varies fromdiverse OKUMA OSPs and different generationsof Heidenhain and Siemens to the controlunits of Mazak. Thorsten Nebbe: “Wheninvesting in CAD/CAM the postprocessorsare mostly the smallest items. However,they tip the scales for the success of millingand are somewhat like the lubricant forevery process chain.”SolidCAM provides theability to tune the postprocessors perfectlyto the CNC machine controllers. This is whystep by step Nebbe wrote perfectly customizedpostprocessors for each machine andeach control unit. “The individual modificationof the SolidCAM postprocessors is easyto learn. We are thus flexible and independentfrom external support.”Functionally, SolidCAM today meets allrequirements that have practical relevanceat Neumag – and that’s mostly 2.5D jobsin all variations. After 5 years of systemmaturation Nebbe in particular praised the“successful integration in SolidWorks andthe practical approach towards NC programming.A CAM system should support programmersin their method of working and notthe other way around. Our NC programmersare experienced machinists.” To quickly tapthe performance potential of the software,management treated each of the would-beCAM specialists to a solid SolidCAM trainingcourse. Nebbe can “strongly recommend toeveryone” this investment, not for example,because the software is complicated, butbecause “the structured introduction conveyedthe philosophy of the software and alot of tips and tricks.”At Neumag every part and every order is different.In order to have the optimal drillingor milling strategy, it’s not infrequent thatup to 10 different home positions have toNeumag has are currently 24 different CNC centres, like OKUMA, Hermle, Burkhardt + Weber, Mazak,Deckel Maho, SHW, all being supplied with NC programs via a DNC network. The range of control unitsincludes diverse OKUMA OSPs, different generations of Heidenhain and Siemens control units and alsocontrol units from Mazak.

Thorsten Nebbe, CAD/CAM specialist atNeumag in Neumünster: “With respect tothe scope of work and the quality of the NCprograms, SolidCAM can hold its own againstsignificantly more expensive systems.”Age is no barrier to CAD/CAM: Erwin Eipel has been building devices for 39 years. The Neumag veteranhas been using SolidWorks+SolidCAM for more than 5 years.be defined in one part, especially whenmachining on 4 and 5-axis centres. Thisis why for Nebbe the “complete automationfor generating” recommended by someCAM vendors “is more of an impediment.Especially for the numerous 2.5D jobs, settinga machining strategy requires a lot oftechnological know-how and practical experience.No matter if we have to machine aluminium,cast iron or high-temperature stainlesssteels on 3, 4 or 5 axes, with SolidCAMwe can incorporate our know-how and turn itinto process-optimized NC programs.”Nebbe appreciates the extensive simulationfeatures of SolidCAM. “The possibilitiesare fantastic, but we try to simulate aslittle as possible and as often as needed.As I said before, the NC programmers hereare well-trained machining experts.” And themachine operators have to follow the directionsof the NC program when clamping aworkpiece.Things naturally look different for true 3Dmachining. Here, the faith in the mathematicalgorithms and the reliablity of the CAM softwareis indispensable. According to Nebbe,SolidCAM is also a very good choice for 3Djobs, but such machining tasks are not themain issue at Neumag. Nethertheless thepeople in Neumünster appreciate to workin 3D. Options like zooming, rotating, colorizing,shading, showing and hiding details,etc. enable the NC programmer to work continuouslyin a comfortable “What-you-see-iswhat-you-get”environment. 3D helps theNC programmer to “understand” a complexworkpiece in minutes rather than in days.“The integrated 3D CAD/CAM environmentsaves us a lot of time. You can, for example,create any cross-section and the dimensionsare right there.”Modern times: Neumag has a Flexible Manufacturing System which supplies the jobs to three modelMA 800 and MS 600 OKUMA machining centres round the clock from a fully automated Fastemspallet warehousing system.Another advantage of the complete, Gold-certifiedintegration of SolidCAM in SolidWorks:CAD and CAM use the same 3D model withmodifications to the part being automaticallyavailable for NC programming. Nebbe: “TheCAD/CAM integration inside the program