Software delivers automotive engine simulation

Building further on its strength in developing the most advanced computer-aided-engineering (CAE) software, Ricardo plc - one of the world's foremost independent automotive engineering and management consulting firms - announced the release of the latest version of its WAVE engine simulation software, version 7.1. This version builds upon the strong base of WAVE 7 - a major upgrade released in 2005 - which brought industry firsts in 3-D pre-processing for 1-D gas dynamics, kinetic aftertreatment models and utilization of networked computers.

Version 7.1 is the fourth WAVE release in three years, representing Ricardo Software's on-going commitment to provide the most advanced 1-D gas dynamics software in the industry. The software will be on display (booth #1938) at the Society of Automotive Engineers (SAE) 2006 World Congress held April 3-6 at Detroit's Cobo Center.

"WAVE 7.1 is essential to the development of the latest fuel-efficient and low-emission vehicles worldwide," said Steve Sapsford, director of Ricardo Software. "This market-leading tool includes significant enhancements in pre- and post-processing interfaces, as well as new models for diesel exhaust aftertreatment, providing additional analytical capabilities for engineers engaged in the development of the next-generation of clean diesels."

Bringing some of the most advanced features and capabilities in one- dimensional gas dynamics, Ricardo's WAVE 7.1 - used in the design of automotive engines and associated vehicle systems - is the latest update to its WAVE engine modeling package. A few of the advanced new features of WAVE 7.1 include:

-- Heat Exchanger Model - The new Heat Exchanger model allows users to enter commonly available performance maps of efficiency and pressure-drop into WaveBuild and WAVE will calibrate the system to produce the expected behavior.

-- R-CAT ECT Models - This feature offers one- or three-dimensional models for the diesel oxidation catalyst and allows users to link to WAVE's diesel particulate filter model to simulate the entire diesel after-treatment system. In addition, the enhanced system introduces the option to link to an external, user-written model, as well as a new link to Reaction Design's KINetics module.

-- WavePost Enhancements - Streamlined handling of multiple WAVE and external data sets and automatic creation of key engineering speed-sweep plots and data tables.

WaveMesher Duct Profile Tool - Viewing tool for the duct diameter profile versus length, to help decide the best discretization of duct sections.

Ricardo Software offers a portfolio of advanced simulation software for engine and powertrain design. Anchored by WAVE, a market-leading engine performance and 1-D gas dynamics code, Ricardo's software suite also includes VECTIS, ENGDYN, VALDYN, PISDYN and RINGPAK. When integrated with industry- standard analysis, computer-aided design and finite element packages, Ricardo Software facilitates the robust "analysis-led design process" practiced by Ricardo and leading original equipment manufacturers around the world.

With its North American headquarters in Van Buren Twp., Mich., Ricardo has been a world-leading vehicle system and powertrain technology provider for automotive manufacturers, heavy-duty manufacturers and tier one suppliers since 1915.

Ricardo is the premium global deep-content engineering and management consulting partner for automotive, commercial vehicle and related industry sectors. The company provides complete engineering services from strategy through product concept, design release and validation, and all phases of the product lifecycle. Ricardo technical expertise lies in powertrain and driveline, vehicle engineering, hybrid and fuel cell technologies, controls and electronics, niche volume manufacturing and advanced simulation software.

Ricardo is committed to excellence and industry leadership in people, technology and knowledge. A public company based in the U.K., Ricardo plc posted sales of $272 million in fiscal year 2005 and is a part of the FTSE techMark 100 index - a group of innovative technology companies listed on the London Stock Exchange. For more information, visit http://www.ricardo.com/.

3D-Tool's New Version V 7.5 is Out Now

Following the success of the greatly enhanced version 7.0, 3D-Tool now announces the release of version 7.5 of its 3D and 2D CAD viewer. “This is not just a small update removing some bugs. Two central features have been completely redesigned, specifically the handling of shells and the measure tools”, states Ingo Wulf, head of 3D-Tool.

More Efficient Handling of Shells and PartsThe new “Element List”, which replaces the “Shell List”, makes it easier to work with complex sets of data. It is now possible to organize shells in assemblies.

Also 3D-Tool V 7.5 supports assemblies when importing STEP and PARASOLID as well as VRML files from PRO/E. The new clear and functional list makes it easier to locate and organize parts, assemblies and shells.

Real 3D Annotations and DimensionsThe two former tools “3D-Notes” and “Measure” have been merged into one new tool “Annotations-Dimensions”.

Instead of temporary measurements, any type of dimension is easily created and can remain displayed on the 3D CAD model. Also it is now possible to show images and/or text on the background.

More Innovations
• New visually striking shade mode: Shaded with black edges.
• New full screen mode for presentations
• Improved 2D-printing with high resolution plotand pen assignments.
• Support of Windows XP Styles
• Improved 3D and 2D interfaces

3D-Tool V7.5 is available in two versions - “Basic” and “Advanced”. The basic version supports common formats such as STL, VRML, SLP and 3DS. The advanced interface additionally supports STEP, IGS, VDA, SAT and PARASOLID files. Both versions support the 2D formats DXF, DWG and HPGL.

Guide To CNC Machines

by: Charles Mohaney


CNC machines are used in a variety of industrial settings and in woodworking shops. Most are out of the price range for the individual user, but can be purchased used for about half the price. These machines increase speed and accuracy when doing large jobs or repetitive tasks.

How CNC Machines Work

CNC machines are used in a variety of industry, manufacturing processes and woodworking shops. CNC routers are used for drilling holes. Some machines have the capability of holding several tools. This allows them to perform more than one operation at a time. They save time and improve accuracy.

CNC stands for Computer Numerated Control. This technology was first seen in the 1970s. The machines need to be programmed and set up properly before operation. Once the initial set up is completed, they are fairly easy to operate and keep running.
In CNC routers, they can be programmed to drill holes in an automatic fashion. This is faster and more accurate over several pieces than in manual drilling. The results are more uniform. This method is very beneficial for larger jobs that require a lot of drilling. Manual drilling can become tiring and when the operator becomes tired, the results can become inconsistent.

Types of CNC Machines

A CNC lathe is a good piece of equipment for cutting wood. These come in models ranging from fifteen to forty horsepower. The amount of power you need depends on the amount of wood you will use with the lathe. The best models operate in several different modes, from completely manual to all CNC. This allows you to tailor the machine’s operation for each project.

A Bridgeport mill is the best in milling technology. Mills are used in many industries, both large and small shops. They are efficient and reliable. Bridgeport mills are built to last a lifetime. However, they are very expensive. The price is out of the range that most people can afford.

The CNC mill is a specialty piece of equipment. It uses computer programming and robotics for accurate operation. The results are more accurate than any person could ever achieve. For this reason, Bridgeport mills are often used in the airline industry. Once the specs are entered, the CNC decides which tools need to be used and automatically changes the tools as needed.
Engraving equipment is made to engrave a variety of materials including glass, stone, metal, wood, composites and many others. The machines mark and engrave with more accuracy than could ever be achieved by hand. Everything from large signs to small lettering can be done, depending on your needs.

Buying Used units

CNC equipment is very expensive and out of the price range of most people. Buying used CNC electronics is an affordable option for some people. You can save nearly 50% or more on some equipment. Be careful when buying used, you want to be sure the equipment is in good condition.
A better option is to look for refurbished equipment. These machines have been inspected at the factory. Any broken or damaged components are replaced. In many cases, the machine is painted and new decals are applied. It’s like getting a new machine for a significantly reduced price. Often, you will get a one year warranty with reconditioned equipment. This gives you time to be sure it is working properly and if not, you can get it fixed for free.

Workholding Blocks enable machining of 5 sides

MagVISE is the best thing to happen in workholding since the invention of the vise! Each MagVISE block uses a powerful, permanent, (rare earth) magnet to securely hold workpieces WITHOUT manual fixturing or vise set-ups. MagVISE uses no electricity, is maintenance free, and will NEVER wear out. See a video of the MagVISE in action at: www.earth-chainusa.com

Each MagVISE block is rated up to 4,620 lbs. of holding power, with a 3.5X safety factor, for over 16,000 lbs. of magnetic force. MagVISE blocks can be ganged together to easily create custom workholding solutions fast. The MagVISE is activated with a simple turn of a wrench.

Features:
o Powerful workholding without all the fuss
o Machine 5-sides AND right through the workpiece!
o Faster setup than vises or fixtures
o Machinable soft jaws for nesting smaller workpieces
o Magnetic holding eliminates workpiece distortion

Benefits:
o Significantly reduce setup times and increase productivity!
o Eliminate need for custom workholding fixtures!
o Machine difficult jobs without complicated setups!
o Accept work you used to turn down!

Delcam to Demo PowerMILL 7 at MetalAsia Exhibition

Delcam will demonstrate the latest version of its world-leading PowerMILL CAM system in Asia at the MetalAsia exhibition to be held, from May 3rd-7th. PowerMILL 7 incorporates new and improved five-axis functionality for both roughing and finishing. Other enhancements include intelligent plunge milling, three-axis swarf machining and parametric surface finishing, together with faster calculation times and easier data management.


For rough machining, the range of five-axis strategies has been increased to match the wide list of options previously available for finishing. It now includes machining to or from a point, orientation through a line or curve, and programming using a reference surface. Using five-axis roughing can significantly reduce the number of set-ups needed to machine many components. It can also be used to give a more efficient cutting angle that will allow more material to be removed with each pass.

In addition, PowerMILL 7 can now generate a five-axis equivalent of any three-axis toolpath. This might be necessary when a three-axis approach is being used for most of a job but where some five-axis moves might be needed to avoid an obstacle or to machine as closely as possible to a steep face.

Better control over the point distribution within five-axis toolpaths has been provided to take advantage of the improved ability of modern machine tool controls to handle large amounts of data. Increasing the number of points in the toolpath can give more even machining with less vibration and more consistent loading on the tool. Both these improvements give a better surface finish and less wear of the cutter.

For both five-axis and three-axis roughing strategies, a new method has been introduced for ordering toolpaths so that air moves are further reduced. This will also make the ordering of rest roughing toolpaths more efficient.

New Mastercam X Wire Brings Efficiency and Speed to Wire EDM Programming

CNC Software announces the release of Mastercam X Wire CAD/CAM software. Built from the ground up, Mastercam X Wire delivers powerful part modeling and EDM programming, efficient tab creation, and dependable wirepath verification. Dramatically streamlined and featuring powerful new features, Mastercam X Wire has been designed to reduce programmer interaction and increase machining flexibility.

Powerful Part Modeling
Mastercam X Wire delivers a new, streamlined CAD engine that makes design work easier than ever before. Geometry that you create is “live,” which allows for modifications until the part is exactly how you want it.

Mastercam X Wire includes:
∙ 2D and 3D geometry creation with complete wireframe and surface modeling.
∙ Associative dimensions update as you change your model.
∙ Extensive editing tools and more.

EDM Programming

Mastercam X Wire includes many tools to increase your programming efficiency.

Some include:
∙ 2 & 4-axis programming.
∙ 2-axis contouring, with or without taper angle.
∙ No-cure cutting.
∙ 4-axis synchronization with automatic skim and reverse cuts.
∙ 4-axis surface finish by chordal deviation, and much more.

Designed for Ease
∙ Full associability lets you modify geometry, tooling information, and machining parameters to get an accurate, updated toolpath.
∙ Mastercam’s Operations Manager provides a single place to create, modify, and analyze all aspects of the toolpath.
∙ User-customizable wire power libraries store power settings and other registers for rough and skim passes.
∙ Store a library of commonly used operations to automate machining.

Multipurpose Robot utilizes R-J3iC intelligent CNC

FANUC Robotics America, Inc. today introduced the new R-2000iB, a multi-purpose intelligent robot designed for a wide range of applications including welding, assembly, part transfer, material removal, and machine loading. The new R-2000iB is compatible with its predecessor, the industry-leading R-2000iA six-axis robot.

Supported by the new R-J3iC Controller, the R-2000iB features enhanced intelligent functions and motion performance. The R-2000iB offers multiple model variations, including a 165kg base model, a high payload version, and a rack-mount model. A slim arm and wrist assembly helps minimize interference with system equipment and allows the robot to operate in small workspaces.

New R-J3iC Controller

Based on the latest FANUC Series 30i CNC Controller, the new R-J3iC Robot Controller uses high-performance hardware and the latest control technology, providing a level of intelligence never offered before.

A new vibration control function virtually eliminates robot vibration during motion. With this function, the R-2000iB can accelerate and decelerate very quickly, reducing cycle time by approximately five percent compared to current robot models. For spot welding applications, the R-J3iC automatically optimizes servo-gun and robot motion, reducing the R-2000iB's cycle time by about 15 percent, which provides significant improvements in throughput and productivity.

Enhanced Intelligent Functions
The R-2000iB offers a variety of intelligent function enhancements including Robot Link, which controls and coordinates up to ten robots through a network exchange of robot positional data. In addition, with the new Radar Monitoring function for multiple robots (available later this year), the R-2000iB exchanges current positional data and robot motion information to prevent interference in multi-robot applications.

"Typically, in multi-robot applications, a customer is required to set up a very complex interlock system between the robots," said Claude Dinsmoor, general manager, controller software product development, FANUC Robotics America, Inc. "The multi-arm and multi-robot enhancements of the R-J3iC can eliminate many complex interlocking systems, simplifying the operation of multiple robots."

Integrated Vision Function
The R-J3iC's integrated vision function adds intelligence to a robot system without the need for additional processing hardware, providing a simple and compact solution with the same high reliability as that of the robot controller.

Integrated vision also makes it easy to use FANUC's Vision Shift, which adjusts an offline program to an actual robot program by using vision, and TCP setup to accurately set tool center points.

"These vision functions can significantly reduce the time required for robot system integration," said Ed Roney, FANUC Robotics' manager of vision product development.

Compatibility with R-2000iA
The R-2000iB robot is compatible with its predecessor, the R-2000iA. The new robot has the same workspace, installation, mounting interface, operation, and robot programming as the R-2000iA. This extensive compatibility makes it extremely easy to replace the R-2000iA with the R-2000iB.

"The R-2000iB is an evolved, multi-purpose, intelligent robot that meets the ever-changing automation needs of manufacturers," said Dinsmoor. "In material handling applications and others, the R-2000iB and its complete array of intelligent functions will help increase the use of robots on the factory floor."

Is It A Mill, A Waterjet Cutter Or Both?

If you remove the cutting head and high-pressure pump from a waterjet cutter, then you’d be left with essentially a machine frame and computer numerical control motion. A CNC vertical machining center also possesses both of these things.

With that in mind, WardJet (Kent, Ohio) recently developed its compact, enclosed M-Series waterjet module that, when installed on a shop’s existing knee mill or VMC, temporarily turns that equipment into a waterjet cutter. According to the company, the conversion takes 20 minutes and requires only sources of water and compressed air at the machine for operation.

The module can be removed as simply as it installs, turning the mill back into a mill.
It’s easy to imagine the inevitable damage that would occur if a waterjet’s abrasive liquid cutting media happened to splash upon vital mill components such as ballscrews. That’s why the M-Series provides a self-contained waterjet cutting environment, isolating the entire cutting operation in a sealed “tent” module to keep harmful media from contacting mill components.
The module bolts to a mill’s T-slot table as would a fixture or vise. The mill must be capable of supporting the entire waterjet assembly’s weight of approximately 600 pounds and provide at least 23 inches of Z-axis clearance to accommodate its height. The base of the module is a shallow tank filled with ball bearings. These dissipate the waterjet stream’s cutting energy, which, on a typical cutter, is accomplished by a deep tank of water.

A toolchanger plate in the top of the tent installs in the mill’s spindle. The system’s waterjet cutting head then attaches to the underside of the plate inside the tent. Once water, air and abrasive lines are connected, then the mill becomes a waterjet cutter.

Two tent versions are available with X-Y work envelopes of 16 by 30 inches and 24 by 48 inches. The larger model allows a standard 4-foot by 8-foot sheet of material to be cut in fourths and loaded into the tent. The workpiece material is supported by grates inside the tent and held in place with a clamping system that accepts workpieces from 0.5 to 4 inches tall.

A 20,000-psi pneumatically powered intensifier pump permits waterjet cutting using existing shop compressed air. This pump, along with an abrasive hopper and electrical box, is mounted on a cart located next to the machine. Larger pumps are also available in 40,000 psi and 60,000 psi versions.

The M-Series is perhaps best suited for shops that currently don’t have a waterjet cutter, possibly because of a lack of available floorspace. The package not only works for mills, but it can also be applied to lasers, wood routers, robotic arms, oxy-fuel cutters, plasma cutters—virtually any type of CNC equipment.

By MMS Online

NVIDIA Professional Solutions

NVIDIA Corporation, the worldwide leader in programmable graphics processor technologies, announced a new line of NVIDIA Quadro FX graphics solutions.

This new line-up includes:
•The NVIDIA Quadro FX 350M – the Company’s first professional GPU designed specifically for thin and light mobile workstations.
•The NVIDIA Quadro FX 1500M – offering outstanding application performance and the industry’s highest image precision and quality.
•The NVIDIA Quadro FX 2500M – bringing an industry best 512MB of graphics memory for customers looking for the highest performance.

This new line of NVIDIA Quadro FX graphics solutions has been selected for the latest generation Dell Precision M90 and M65 mobile workstations. These represent the most powerful mobile workstation solutions ever offered by Dell, delivering a broad range of performance and features in a mobile platform for on-the-go Engineers, Artists and other Professionals.

“The Dell Precision M65 and Dell Precision M90 offer the flexibility, performance and reliability that are demanded by customers in industries like Computer-Aided Design and Engineering, Scientific Research or Digital Content Creation,” said Darrel Ward, director, Dell Precision Workstations. “Uncompromised performance was our goal for the new Dell Precision M90, now the industry’s most powerful mobile workstation. The new Dell Precision M65 delivers the latest technology, features and performance in a package that is measurably lighter than its predecessor. Together, these two new mobile workstation products offer a full range of solutions that will address the diverse requirements of mobile professionals.”

NVIDIA Quadro FX mobile solutions offer the same features found in NVIDIA workstation graphics industry leading solutions for desktop-based professional workstations, which have long been the choice of professional application users. These include exclusive features like 12-bit sub-pixel precision and full 32-bit floating point precision, as well as a host of unequaled capabilities that NVIDIA Quadro desktop-based users have simply become accustomed to.

“Mobile products are our fastest growing segment as our customers realize the productivity benefits of taking their work wherever they need to be,” said Jeff Brown, general manager for NVIDIA professional products. “NVIDIA introduced the industry’s first mobile workstation graphics solution back in 2001 – this year we will be delivering a range of products that will enable our partners like Dell to make this the biggest year ever for the rapidly expanding mobile workstation segment.”

Laser Scanning System features high definition design

NVision has announced the introduction of a High Definition version of its MobileScan 3D laser scanning system which moves the capability of 3D laser scanning into fields that it was not accurate enough for in the past. The new HD scanner provides very high resolution with a point spacing of 0.001" and an accuracy of +/- 0.0005" while collecting measurements at a rate of 30,000 points per second.

"The High Definition version of the MobileScan 3D provides a higher accuracy inspection and reverse engineering system than has been available in the past," said Steve Kersen, President of NVision. "Customers no longer need to choose between the speed of a scanner and the accuracy of a CMM."

The MobileScan HD sensor has a 2-axis servo controlled swivel head that is integrated with a turntable. Movement of these three axes is programmable allowing automation of measurement strategies. The key to the system's accuracy is that it uses only one servo and rotary encoder at any one time and these components are manufactured to the highest specification available. "By minimizing the opportunities for error to be introduced; the highest level of accuracy can be achieved," said Giles Gaskell Director of Business Development for NVision.

The sensor can be moved manually or automatically controlled to follow a pre-defined measurement strategy. This means that the scanner can be left alone to scan production items without the constant attention that is required by a handheld device. The sensor projects laser light onto the surface of the object being measured while a camera continuously triangulates the changing distance and profile of the laser capturing points at a rate of 30,000 per second. The density of the resulting "point cloud" is what enables the object to be accurately replicated. Before scanning and during the measurement process, the new laser scanner continually senses the object's surface and ambient light conditions and automatically adjusts the sensor to obtain the best possible measurements. All measurements are automatically transformed into a common coordinate system meaning that there are no patches of data to be sewn together after scanning has taken place.

MobileScan HD connects easily to a standard notebook computer via USB or Firewire. The new scanner comes integrated with Geomagic computer-aided inspection software that automatically processes scan data from a physical part to generate highly accurate polygon and parametric surface models. The Geomagic software also provides easy-to-understand graphical comparisons between CAD models and as-built parts.

"The MobileScan HD is a logical extension to NVision's range of Laser Scanning products, offering our customers the high speed data collection of a laser scanner with the accuracy of a CMM for the first time," said Gaskell.

The Hard-Milling Imperative

Corey Greenwald “gets it.” He understands that hard milling is becoming an essential capability for shops producing plastic injection molds. He understands how to perform hard milling operations effectively, routinely and confidently in his own shop, Hard Milling Solutions. He understands that as mold shops turn to hard milling, they are likely to need such a specialty shop to handle the hard milling they can’t handle, either because they do not have enough time on their own machines or because they aren’t quite ready to perform hard milling on their own.

Unfortunately, when it comes to hard milling, many mold shops don’t “get it” yet. They are stuck doing mold machining in traditional ways. As a result, they end up spending time hand polishing molds and then spending more time struggling to “spot” the molds in final trials and tests.

“All these extra hours represent the difference between competitive and non-competitive moldmaking in a global market,” Mr. Greenwald says. “Unless these shops change their machining methods, they are going to have a hard time surviving,” he concludes.
Mr. Greenwald strongly believes that hard milling is one of the most important answers to this problem, especially in smaller molds and inserts. He says that hard milling can help a mold shop start with hardened steel and produce finished mold surfaces that require little or no hand polishing. That allows them to skip several time-consuming, labor-intensive steps in the moldmaking process. Hard milling capability, he adds, is also a boost to machining shutoff surfaces on one side of the mold to a “negative stock” condition. This leaves a slight gap between mating mold surfaces, thus greatly reducing the time and effort to do the final alignment and adjustments (spotting) of the mold when it is first in the press. The mold will last longer and run faster, too.

“By applying hard milling properly, a mold shop should be able to take mold components off the machine tool, assemble them, put them in the injection machine and get a good part with the first shot.” Mr. Greenwald says. “With hard milling, a mold shop can take time and cost out of both the machining and the spotting of plastic injection molds.”
So what’s to get about hard milling? According to Mr. Greenwald, hard milling requires a whole new kind of thinking about how to machine metal. Hard milling takes a certain kind of machine tool, a certain kind of cutting tool and toolholder, and a certain kind of programming software. All of these pieces of technology have to be in place, and all of them have to work together perfectly.

“Once you get everything going and understand how it fits together, hard milling is a reliable, predictable and productive process,” Mr. Greenwald says. As proof, he points to the fact that his shop’s two vertical machining centers (designed especially for the demands of hard milling) often run virtually around the clock with minimal attention.

A Shop Is Born
How Mr. Greenwald became a highly respected practitioner and strong proponent of hard milling is an unusual story. He started out as a manufacturing engineer, eventually getting involved in shop management at a die/mold shop in the suburban Detroit area. One of the projects he oversaw was the installation of a machining center to hard mill forming punches for hot-forged powdered metal connecting rods.
The results were impressive. Production of the punches dropped from 30 days to 6. This was better than what the shop owners expected, and it was as far as they wanted to go. Mr. Greenwald, however, saw even more potential to save time and cut costs with hard milling.
Around the same time, Craig Sizemore, one of Mr. Greenwald’s friends in the Detroit die/mold community, was also taking an interest in hard milling. His shop, Cut-Rite EDM, Inc., specializes in advanced wire electrical discharge machining (EDM), and he was exploring hard milling as a complement or alternative to EDM. Mr. Sizemore believed that a counterpart to his EDM shop was needed to service shops looking for hard-milling capacity and experience.

With Mr. Sizemore’s support, Mr. Greenwald opened Hard Milling Solutions in Shelby Township, Michigan, about 30 miles north of downtown Detroit. That was in August 2004. Hard Milling Solutions operates in leased space next door to Mr. Sizemore’s shop. Unlike Mr. Sizemore, though, Mr. Greenwald was not trained as a machinist or tool and die maker. His only experience working closely with machining was related to the hard-milling application at his former employer.

This encouraged, rather than deterred, Mr. Greenwald. He knew enough about hard milling to realize that it had to be approached with the same rigorous discipline and vigorous curiosity that sustained him as a manufacturing engineer. That still left him with the practical aspects of learning how to perform hard milling and of equipping a shop to do it effectively. For that, Mr. Greenwald turned to Single Source Technologies, an Auburn Hills, Michigan, distributor of machining centers and EDM equipment from Makino (Mason, Ohio) and other builders. Single Source had been active in promoting high speed machining and hard milling in the metro Detroit area and had helped Mr. Greenwald set up the hard-milling machine with his former employer.

He attended the workshops and training courses about high-performance machining at Single Source, and he credits this training as the basis for his success in hard milling. When Hard Milling Solutions went into operation, it was with a Makino V56 machining center and one employee to help run this machine.

Although Mr. Greenwald got his start with the help of these outside forces, he quickly realized that hard milling still required a lot of pioneering on his part. Because the shop was set up to specialize in hard milling, he began encountering a variety of hardened steel grades that ranged into the 60s of the Rockwell hardness C-scale. The machining data tables from Single Source gave him a starting point, but much of the work required experimentation and test cuts.

Today, about half of the shop’s work is in plastic injection molds, most of this using hardened H13 and S7 tool steels. The shop also specializes in medical machining, including joint replacement forging dies as well as die details, die-cast core cavity inserts, powder metal tooling end forms and anything as hard as 65 Rc. The original machine has been joined by a second V56. Mr. Greenwald continues to keep both machines in operation with one other employee, Kevin Hunter, a mold maker with 30 years of experience.

Because hard milling is all his shop does, Mr. Greenwald says he could hardly help becoming a rather advanced expert at it. Even so, for selfish and unselfish reasons, he wants to see hard milling more widely adopted by mold makers in the United States. He believes that, as more shops invest in this technology, they will be more likely to turn to his shop with overflow work or particularly difficult jobs. More importantly, he believes that hard milling represents the future of moldmaking in this country. “Right now, there’s no better way to make moldmaking profitable in the face of surging mold imports from low-wage countries,” he says.

Hard Milling In A Nutshell
Hard milling is an offshoot of high speed machining techniques. The essence of high speed machining is taking many light cuts at closely spaced stepovers, thus leaving minimal cusps between passes. The goal is to create an as-machined surface that drastically reduces the need for subsequent processing. For the cutting tool to achieve an effective chip load, feed rates and spindle speeds must be much higher than those normally applied in traditional machining; hence the name high speed machining. The high feed rates also make it possible to complete a much larger number of passes across the workpiece more quickly than with traditional methods.

Hard milling takes the concept of high speed machining one step further. The combination of light cuts at high feed rates and spindle speeds makes it possible to remove steel in the hardened state efficiently when all of the proper conditions are met. Likewise, closely spaced stepovers with small-diameter, radiused tools leave a surface that approaches the fineness of one that has been stoned or polished by hand. (Mr. Greenwald reports routinely achieving surfaces of 10-12 rms with hard milling when needed.) Because the steel is already hardened, subsequent heat treating, stress relieving or grinding steps are unnecessary. More importantly, the process also replaces many costly steps with EDM.

The ability to hold extremely tight tolerances (±0.0004 inch or less) is an added benefit of hard milling that is valuable in mold machining. It allows mold contours to be machined without the excess stock normally left for hand spotting. Moreover, by machining to zero stock, mold geometry will perfectly match that of the CAD model. Likewise, this ability allows mating mold surfaces to be machined to a negative stock condition. The concept is to machine shutoff areas along the parting lines, usually on the cavity side, slightly but precisely below the nominal dimension. This leaves a small gap between the surfaces that would normally contact each other when the mold closes. Gap size is too small (0.0008 inch is typical) to allow plastic to flow out during the injection process, so the mold still shuts off effectively. The gap allows air within the mold to escape readily, without additional provisions for venting, as molten plastic is forced inside. Small contact pads in corners maintain the gap—otherwise, shutoff surfaces do not touch each other. The interference between these surfaces that must normally be resolved during spotting and fitting is eliminated. In addition, the gap eliminates the impact between these surfaces when the core and cavity sides come together so that the sharp edge at the parting line is fully protected.

From The Tip Up
Like any CNC machining process, hard milling depends on a capable machine tool, the appropriate cutting tool/toolholder system and an effective toolpath program. Unlike other machining processes, however, the interaction of these elements is somewhat more complex and dynamic, although certainly not beyond the reach of new users approaching it with determination, commitment and openness to change, Mr. Greenwald says.

“Getting a grip on hard milling can be a challenge, but there is one way to get your mind around it,” he points out. The way to understand hard milling, he says, is to understand that it is all about protecting the tip of the cutting tool. “It all boils down to what makes the tip cut safely and effectively. If you understand that, then you can work backwards and understand the system requirements and their interactions. You manage all of those interactions so that the tip of the end mill cuts coolly and freely, with consistent engagement in the material. Everything else falls into place.” That said, he adds that if any part of the system is neglected or breaks down, then the tip of the cutter suffers and the whole process starts to fail.

Working up from the end mill, Mr. Greenwald outlines the critical factors in each element.

The cutting tool. Hard Milling Solutions typically uses ballnose end mills for roughing, semi-finishing and finishing. Two-flute ballnose end mills are used exclusively for finishing, and these finishing cutters are the most critical elements in the hard-milling process. For finishing, the end mill must meet two essential requirements: it must have a near-perfect radius and have virtually unblemished cutting edges. Accuracy of the radius has to be extremely tight so that a high or low flute does not cause uneven metal removal, thus degrading geometry, surface quality and tool life. The end mills used in the shop for finishing are certified to a radius accuracy of at least ±5 micron (±0.0004 inch). On occasion, the shop has used end mills 0.012 inch in diameter with a radius certified to ±0.0002 inch.

The cutting edges of the flutes must have a minimum of microscopic chips, cracks or other irregularities. The presence of these defects means that the edges will be subject to accelerated wear mechanisms as soon as they contact the workpiece. This leads to a rougher surface finish and a shortened tool life. Tool life is an issue because the shop depends on its end mills to last as expected when running its machines unattended.

Cutting tools that meet these specs are now readily available from suppliers such as OSG (Glendale Heights, Illinois) and NS Tool (distributed in North America by Single Source Technologies), but they are considerably more expensive than standard items. Because tools of this quality are absolutely necessary, however, cost is not an issue. “They are the foundation that makes it possible to skip polishing and spotting down the road, so they are an essential investment in the hard-milling process,” Mr. Greenwald says.

The toolholder. The toolholder has to protect the radius and edge quality of the end mill. Mr. Greenwald believes that shrink-fit toolholders with HSK interfaces provide the most protection. Shrink-fit clamping provides the lowest runout of any current clamping method, thus minimizing the slight off-center rotation of the cutting tool. Runout causes the tool to cut excessively with one flute, thus increasing the chip load on that flute and shortening cutter life.

Hard Milling Solutions uses a Haimer shrink-fit system. According to Mr. Greenwald, it takes less than a minute to exchange and reclamp cutting tools and return them to the automatic toolchanger. In his experience, shrink-fit clamping routinely holds runout to less than 0.0001 inch.

The shop buys only balanced HSK toolholders and avoids any abusive handling. The HSK interface is mandatory because it provides stiffer, more accurate and more secure clamping in the spindle than other tapered styles.

The spindle. Just as the toolholder protects the end mill’s sharp edges and accurate radius, the spindle in turn has to protect the integrity of the cutting tool/toolholder assembly. Of course, the spindle also has to be designed for the high rpm that hard milling requires. Controlling heat and vibration in the spindle is very important. Direct-drive spindles (no gears or belts for power transmission) and internal cooling are usually dictated by hard-milling applications.
The pair of V56 vertical machining centers installed at Hard Milling Solutions has spindles with these features. Both spindles are rated at 20,000 rpm.

Machine construction. Discussing the spindles on these machines can’t be separated from a discussion of the overall machine construction of which they are a part. “It almost goes without saying that machines for hard milling have to be extremely rigid,” says Mr. Greenwald. Volumetric accuracy is also important.

The machines in his shop are designed especially for the thermal stability and rigidity demanded by his applications. Some of the construction features that distinguish these machines from general-purpose models include:

• Heavy base and column (these models weigh more than 20,000 pounds)


• Core-cooled spindle


• Box ways with linear roller bearings


• Dual supported ballscrews

“From my perspective, what is important is minimizing the vibration and tolerance stack-ups that might reach the cutting tool. Whether I’m cutting with a 0.5-mm end mill at 40 ipm or a 6-mm end mill at 380 ipm and holding accuracy in the tenths, the effects of system variables are magnified. Everything has to be controlled,” Mr. Greenwald says.

The CNC processors and servo systems on these machines are also designed for hard milling. Pertinent features include:

• Dual RISC processors, one of which is dedicated to the data transformations necessary to turn programmed tool paths into servo commands.


• Look-ahead capability of 120 blocks to avoid over- or undershoots in tool travel.


• Effective interpolation of high-resolution encoder feedback for precise position control.


• Glass scales for feedback in 50 nanometer increments.

Programming Software
However, the performance of a rigid yet responsive machine tool depends on the NC programming input. This leads to what Mr. Greenwald considers one of the least understood aspects of hard milling—the influence of the tool paths driving the CNC.

“It all goes back to the tip of the cutting tool, where we started,” he explains.

The perfect radius and edges of the cutting tool rely on a “smooth ride” to cut safely and accurately when machining hardened materials. This is why most CAM software is inadequate for hard milling. The algorithms that generate tool paths are not designed for the smooth, accurate moves to the tolerances required for the kind of hard milling that allows mold shops to bypass entire steps of the moldmaking process.

As Mr. Greenwald sees it, typical CAM software is designed to produce tool paths quickly, so most systems use processing shortcuts that generate code efficiently. This software is great for general milling applications, because the effects of these shortcuts don’t matter. The output is more than accurate enough for this kind of work. The problem is, this virtue becomes a vice in the realm of hard milling, he says.

His shop uses CAM-TOOL as its programming software. This software, developed in Japan, is sold in the United States by Graphic Products North America, which is located in Windsor, Ontario, and led by Randy Nash, its new president. Chris Renaud, one of the company’s sales and applications specialists, has worked with Hard Milling Solutions and understands its applications. “Corey’s shop typifies the needs of hard milling, especially for mold work,” he says.

According to Mr. Renaud, this software does not create a triangulated mesh approximating the surface of contoured geometry because these approximations stymie the accuracy needed for hard milling, which is measured in millionths of an inch. Instead, the software calculates the tool path based on points taken directly from the geometry. In fact, he says, the points are connected by mathematically defined curves that best fit the points, as opposed to using straight line segments that connect the center points of each triangle in a mesh laid over the contours. Because the resulting path is a series of curves, the motion defined in the tool path lacks abrupt changes in direction that short line segments create. A machine tool with nanometer feedback resolution will attempt to move along those segments without compromise, creating a jerky, stuttering effect that puts cutting tools at risk.

Effective tool paths for hard milling have other requirements, according to Mr. Renaud. They must:

• Control how the cutting tool enters and exits the cut;


• Maintain a constant chip load by controlling the engagement of cutting edges with workpiece material; and


• Provide constant stock conditions for each subsequent roughing or finishing pass.

Algorithms for accurately analyzing the as-machined shape of the workpiece geometry are the key to meeting these goals, Mr. Renaud says. Tool paths for hard milling must not create the conditions that work against the ability of the cutting tool to generate the accuracy and surface finish that can take a mold right to the press.

Add It All Up
When the chain linking the tip of the cutting tool to the programming software has no weak links, hard milling becomes predictable and reliable. This is why unattended operation is feasible. It’s a practice that Hard Milling Solutions does, literally, day in and day out. “For each machine, we average about 100 or more hours a week of minimally attended operation,” Mr. Greenwald says. About 90 percent of all jobs are run totally unattended. “If you have to stand in front of the machine on these jobs, then they weren’t programmed correctly,” he says. The only time he or Mr. Hunter watches a job closely is when one of the men is experimenting with smaller cutters or harder materials than previously encountered and he needs to learn all he can about system performance.

He stresses, however, that routinely operating in the unattended mode is not an option or a bonus with hard milling. He says that running almost around the clock is the only way to make the machines pay for themselves and provide a healthy return on the investment. Unattended operation represents more than high machine output with low labor input. It also represents numerous hours of benching and spotting at high labor costs that have been taken out of the process.

The benefits to the mold-buying customer are so compelling that hard milling should be irresistible to the mold builder. By eliminating or drastically reducing electrode milling, EDM, grinding, polishing and spotting on the press, hard milling takes out some of the most expensive and time-consuming steps in the mold-building process. For this reason, Mr. Greenwald considers hard milling to be a make-or-break technology for U.S. mold shops.
Their survival ensures his because he knows that there will be plenty of extra hard milling work or unusually difficult jobs that will come his way.

By Mark Albert - http://www.mmsonline.com

MAC-The Designer’s Dream

Coupled with some of the industry’s most powerful drawing and building design applications, like Graphisoft’s ArchiCAD or Nemetschek’s VectorWorks, the Power Mac G5 lets your imagination take flight. Use SketchUp to quickly develop, modify and present 3D models. Work in Piranesi to turn simple 3D renderings into beautiful, high quality 3D images. Or employ FastTrack Schedule 8 to manage your workflow and projects.

You can also take advantage of the most popular office productivity tools such as Microsoft Office, QuickBooks and FileMaker Pro. And with Mac OS X, you can work worry-free, knowing that your system contains one of the most stable operating systems in the world. Virtually immune from viruses and system crashes, Mac OS X reduces IT support calls and computer downtime.

MAC CAD-Building Information Modeling

Graphisoft ArchiCAD
Graphisoft®’s flagship product ArchiCAD®, built by architects for architects, is a solution for building design professionals. ArchiCAD’s unique Virtual Building approach combines 3D design capability with intelligent object technology and specific tools for visualization, presentation and construction documentation — all completed in a single model to allow you to be more productive and win business.

Nemetschek VectorWorks Architect 11
VectorWorks ARCHITECT 11 offers new tools and technology that dramatically reduce the amount of time and effort you spend in creating drawing sets. The updated software improves drawing coordination, makes it easier to import and export files and adds new technology to help you better communicate your design intent.

PowerCADD
PowerCADD is an intuitive, elegantly engineered CAD software solution. Modular in design, with trade-specific plug-in tools and commands called Externals, PowerCADD provides unsurpassed flexibility, allowing customization for your needs. Easy to learn, allowing you to focus on your design rather than how the application works. If you can imagine it, you can do it in PowerCADD.

VersaCAD
VersaCAD is a practical and versatile computer-aided-design and drafting (CAD) software package. It is suited for architectural, engineering, design and mapping applications, as well as for operational documentation such as facility planning, catalogs, installation guides, and network schematics. VersaCAD is interoperable with other CAD files through Vlink, which translates between VersaCAD, DWG, DXF and IGES formats.

Single Board Computer offes dual, dual-core CPU capability

WIN Enterprises, Inc., a leading designer and manufacturer of embedded controllers and platforms for OEMs, announces the MB-06048, a PICMG 1.3-style Single Board Computer (SBC) that can be powered by one or two single- or Dual-core AMD Opteron(TM) processors. The new SBC features PCI Express(TM) and PCI-X® 64-bit/133 MHz support, plus on-board video and 3-port LAN capability.

The WIN Enterprises MB-06048 provides OEMs with a powerful general computing platform in a compact package. A stackable HyperTransport(TM) technology-based extension card can support a second CPU to provide the dual, dual-core CPU configuration - four processing cores - for support of processing intense applications.

"The growing market for single board computers in medical imaging, military systems, and custom, unique form factors grounded on industry standards like PICMG 1.3 and increasingly requires a high-performance processor," said David Rich, director of 64-bit Embedded Business at AMD. "The combination of WIN's design and manufacturing expertise and the AMD Opteron processor gives these markets an easy-to-develop platform with industry-leading performance-per-watt."

Features
· Small board size: 13.330 in. x 4.976 in.; 33.86 cm x 12.64 cm
· Single, dual-core, or two, dual-core CPUs requiring low to high power (30/55/95 W)
· On-board video integration: ATI 64MB M9 graphics
· Three 10/100/1000 Gigabit Ethernet LAN ports; Four USB ports
· NVIDIA nForce Professional 2200 chipset
· 4X SATA with RAID
· 16-lane PCI Express slot, PCI-X 64-bit/133 MHz
· 2 memory slots with up to 8GB
· Standard IDE interface
· Supports Linux Debian 64 and Windows XP 32- and 64-bit operating systems

Pricing and Availability

Three weeks for product delivery after order. A MB-06048 SHB that accommodates one single- or dual-core AMD Opteron(TM) processor costs $1,000; Configured with a CPU extension board adds an additional $250. These prices are without CPU's and memory.

Mastercam Provides a New Multimedia Section on Web

CNC Software has added a new Multimedia section to the Mastercam.com Web site. This page gives customers the opportunity to explore some of the latest features in the Mastercam X family with downloadable video demonstrations, narrated overviews, and documents highlighting powerful new tools.

The Introducing Mastercam X video was initially introduced on the Mastercam X release CD. In the video, discussion entails not only what’s new for existing customers updating to the new, powerful, streamlined flow and flexibility of Mastercam X, but provides a broad based overview of what Mastercam can do for new customers. The 27-minute video covers five distinct areas. The first segment covers the new Mastercam X interface and helps demonstrate both how to use it and why you may want to use it in specific ways. The second and third sections of this video provide actual workflow demonstrations of 2D and 3D design using Mastercam X’s highly graphical and flexible Sketcher tools. The fourth and fifth sections of the video provide a basic overview of the new streamlined processes for selecting and machining your imported or newly developed modeling data.

The What’s New videos from the latest Mastercam release (MR1/SP2) are also included on this page. These narrated videos highlight the new functionality in Mastercam X MR1/SP2, including the new high speed surface toolpaths (HST) and Mastercam Wire. They require Macromedia Flash and are best viewed at 1280x1024 screen resolution.The newest addition to this Web page is the Machine Definition/Control Definition Toolkit. The toolkit consists of 3 parts:

• MD/CD Overview Videos - These videos introduce you to the overall concepts, vocabulary, and workflow of Mastercam X's machine and control definitions. Requires Macromedia Flash and are best viewed at 1280x1024 screen resolution.
• MD/CD FAQ Videos - These videos highlight frequently asked questions about machine and control definitions in Mastercam X, including how to change your post processor. Requires Macromedia Flash and are best viewed at 1280x1024 screen resolution.
• Working with Machine and Control Definitions – This PDF (Adobe Acrobat) file provides step-by-step instructions and additional background information on machine and control definitions in Mastercam X.

For more information visit: www.mastercam.com