In the aerospace industry, composite materials have emerged on the fuselage, wings, vertical tail and control surfaces to a much greater degree over the last few years. Coast Composites Inc., part of the UK-based Hampson Industries Plc, supplies Invar tooling, as well as resin transfer molds and mandrels used in the composite lay-up and manufacture of today’s advanced flight critical aerospace structures. On the large, long bed CNC gantry mills used at its main facility in Irvine, California, the company claims high accuracy on even the longest wing skins. On its largest CNC mill, a German-built Handtmann five-axis machine that uses twin Siemens Sinumerik 840D numerical controls, accuracies are to +/- 0.003 in. on the longest runs. The Handtmann gantry mill can accommodate structures to 22 ft wide x 75 ft long x 84 in. high.

By using the touch probe and CNC, in conjunction with its proprietary temperature compensation program, Coast Composites “…turns every machine tool into its own coordinate measuring machine,” said company founder, Jerry Anthony.

“Even though Invar tooling is the industry standard for composite lay-up, owing to its low coefficient of thermal expansion, you still get thermal growth over the long distance runs we process,” said Paul Walsh, president, Coast Composites.

To maintain accurate machining even with thermal growth, Coast engineers developed a temperature compensation system to adjust the go-to points from the control for real-time temperature on the machine and the work piece. The data covered all aspects of machining, from material composition to acceleration/deceleration mapping and the temperature variations over the largest pieces and longest machine cycles.

The showcase machine tool at the Coast facility in Irvine is a Handtmann five-axis CNC long bed gantry mill, capable of running structures to 22 ft W x 75 ft L x 84 in. H, using a powerful 80 hp, 60 kW spindle up to 15,000 rpm. The 40,000 lb bridge can move at 2200 ipm. Using the Siemens CNC onboard and its own proprietary temperature compensation system, Coast achieves a better than +/- 0.0003 in. accuracy on wing skin tooling and other structures that often occupy the entire machine bed.

In the temperature compensation system, laser tracking operates in tandem with Valisys inspection software. A Siemens CNC engineer wrote the machine tool inspection interface software. The CNC runs real-time inspections and data analysis, essentially turning every machine tool into its own coordinate measuring machine. The laser tracker is now used primarily for final checking.

http://www.designworldonline.com/articles/6963/10/Custom-CNC-Turns-Every-Machine-into-a-CMM.aspx

Company directors David Holden and David Johnson have extensive experience across both product ranges.

Mr Holden has provided extensive 5-axis, cell, system engineering and turnkey engineering support to many of the UK’s leading aerospace, defence, automotive related and toolmaking companies. He has previously held positions as technical director, general manager and director within the machine tool industry.

Mr Johnson has spent the last 20 years, latterly as a general manager, providing front line service support for Toyoda and Mitsui Seiki product ranges in which time he has established a high reputation with customers in ensuring key production machines maintain their high orders of spindle utilisation and uptime. He has also provided and co-ordinated re-engineering and retooling services to meet changes in production requirements.

The Toyoda range of grinding machines is heavily production orientated with the ability to provide long periods of process consistency. With a wide installation base meeting the demands of the automotive sector, machines can be specified in universal, cylindrical and highly specialised crankshaft including twin-headed variants and camshaft grinding machines.

The Mitsui Seiki range of machining centres span horizontal and vertical spindle types with both available in 5-axis configurations. There is also a range of high speed linear-driven, precision, vertical machining centres and the company builds jig borers and grinders plus an extensive range of internal and external thread grinding machines.

Based in Rushden, Northants, 2D CNC Machinery has responsibility for sales, installation, service and on-going customer support.

CGTech will feature version 7.1 of VERICUT CNC Machine simulation software on Stand 1647 at the Midlands Design and Engineering Show at NEC Birmingham on April 6^th and 7^th 2011.

VERICUT is CNC machine simulation, verification and optimisation software that enables users to eliminate the process of manually proving-out NC programs. It reduces scrap loss and rework. The program also optimizes NC programs in order to both save time and produce higher quality surface finish. VERICUT simulates all types of CNC machine tools, including those from leading manufacturers such as Mori Seiki, Mazak, Makino, Matsuura, Hermle, DMG and Chiron. VERICUT runs standalone, but can also be integrated with leading CAM systems such as Catia V5, Siemens NX, Pro/E, MasterCAM, EdgeCAM, open Mind HyperMILL  and Delcam PowerMill.

“VERICUT 7.1 builds on CGTech’s highly successful VERICUT 7.0 release and subsequent point releases that contained over 700 customer requests delivered throughout 2010,” says CGTech Ltd Managing Director, John Reed,  “Version 7.1 contains nearly 200 customer requests and further improvements to VERICUT’s user interaction, simulation capabilities and analysis, cutting tool creation, and CAD/CAM integration.”

A few of the many features coming in VERICUT 7.1 include the ability to record and display cutting conditions, the addition of multiple turning orientations and specialty cutting methods, and improvements to simulating complex subroutines and advanced CNC control features in VERICUT. There has also been an emphasis placed on simplifying the creation of VERICUT reports. With the new VERICUT report enhancements, users can preview and customize their own reports to include features such as pictures, videos, links to files and WebPages. These reports have become increasingly valuable for VERICUT users to share CNC machining process information throughout their organization and supply chains.

A new feature in version 7.1 is the VERICUT reviewer. This allows a recorded animation file of the machining process to be played on any PC without requiring a VERICUT license to be present. In addition to playing the animation the user can use analysis features to examine the cut model and to zoom and pan around the display.

http://www10.mcadcafe.com/nbc/articles/1/925896/CGTech-Will-Feature-V7.1-VERICUT-CNC-Machine-Simulation-Software-Midlands-Design-Engineering-Show

VERICUT 7.1 features significant enhancements to reduce the time required for manufacturing engineers to easily develop, analyze, inspect and document the CNC programming and machining process. Along with proactively adding new features, CGTech developers and engineers focused on addressing hundreds of customer-driven enhancements.

VERICUT Product/Function Overview:
VERICUT is CNC machine simulation, verification and optimisation software that enables users to eliminate the process of manually proving-out NC programs. It reduces scrap loss and rework. The program also optimizes NC programs in order to both save time and produce higher quality surface finish. VERICUT simulates all types of CNC machine tools, including those from leading manufacturers such as Mazak, Makino, Matsuura, Hermle, DMG, Mori Seiki, Makino and Chiron. VERICUT runs standalone, but can also be integrated with leading CAM systems such as Dassault Systemes Catia, Siemens NX, Creo (Pro/E), MasterCAM, EdgeCAM, Delcam PowerMill and Open Mind Hypermill.

Tool Manager
To further simplify creating a VERICUT tool library, CAD solid models of inserts and holders can be imported into VERICUT. The new feature added to the Tool Manager displays the CAD Geometry window that allows easy identification of which parts of the CAD model file corresponds with holders, cutters, or inserts. CATIA and STEP models are supported.

It is now possible to create and display coordinate systems in the Tool Manager. These coordinate systems can then be used to align tool components.

CAD Model Assembly
A new feature, Assembly, in the Open model file selection window enables the user to extract all individual components of a CAD assembly file and store them in their own model definitions. If Assembly is toggled “on” (checked) a separate model will be created for each component in the CAD model. When toggled “off” (unchecked) all components are used to create a single model. This feature supports STEP, CATIA, and Siemens NX model types.

VERICUT Reviewer
The VERICUT Reviewer incorporates all the functionality of NC Review mode in a stand-alone viewer that does not use a VERICUT license. The Reviewer can play forward and backward while removing and replacing material. Error messages and NC program text is highlighted when a collision on the stock or fixture is selected. An NC program line display is optional. The user can rotate, pan and zoom just like normal VERICUT, and the cut stock can be measured using all the standard X-caliper tools. The “Reviewer” file can be saved at any point in a VERICUT session.

Cutting Conditions Shown
Cutting conditions are shown in the status display and available when stepping through the program using NC Program Review. The feature shows detailed information about the cutter’s engagement with material, including: axial depth, radial width, volume removal rate, chip thickness, maximum surface speed and contact area.

CNC Process Documentation
With the VERICUT report enhancements, users can preview and customize report templates to include features such as pictures and videos and links to files and websites. These reports have become increasingly valuable for VERICUT users to share CNC machining process information throughout their organisation and supply chains.

Machine Simulation
A new feature has been added for VERICUT collision checking: it is now possible to stop the simulation at an “exact” collision point between the machine components. While simulating an NC block with the Stop At Collision box checked, VERICUT will stop in mid-motion at each collision point. Clicking the Step button continues simulation to the next collision point (or to the end of the motion if no other collisions exist).

Additional Enhancements:

• Project tree enhancements including a new UNDO function
• The Pro/E interface has been enhanced to improve creation of parametric, sketch, and solid tools.
• Helical milling material removal is enhanced by creating a “true helix” motion type.
• Material removal for general gear cutting and broaching operations is supported.
• Simulation of back spot-facing tools is now supported.
• Diameter value is added to hole measurement information in X-Caliper.
• VERICUT now supports a full range of six-axis robots to simulate machining, waterjet trimming, fibre-placement, drilling and fastener insertion.
• A general linkage component is added to allow the connection of two driven components with a slaved linkage.
• The ability to output a NC program, of a different format than the input program, is added to base VERICUT functionality. The method for re-formatting the program is user-configurable.
• All popular controls continue to be enhanced with new advanced features: Siemens 840D, Fanuc 30’s, Heidenhain, Okuma OSP, Mazak Matrix.
• http://www.machinetoolsonline.com/article.mvc/CGTech-Announces-The-Next-Major-Version-Of-0001

Denver , the San Marino based innovative manufacturer of CNC machines has launched KREA, the ultimate addition to its already comprehensive range of hi-tech machines.

KREA features a small footprint design capable of working glass of size up to 2100 x 1100 with possibility of grinding, edging, drilling and polishing glass thickness up to 25mm.

With its powerful 9.2Kw electrospindle and 14 positions automatic tool change KREA suits the smaller glass shop with limited floor space as well as larger companies eager to improve productivity and cost-effectiveness in relation to batch and workpiece size.

Denver is worldwide renowned in the glass industry for the superior engineering of its machines thanks to its long standing experience in the stone working machinery industry where mechanical sturdiness and reliability are key factors. Describing the machine, Adolfo Fabbri engineering manager in DENVER said “ KREA is the best match for the modern, seamless fabrication of shower doors, home appliances and interior design items. Let alone state-of-the-art components such as  digital electronics, monobloc steel chassis and user-friendly cad cam software, KREA features the best operating/footprint area ratio in its category and recyclable soundproof and rustproof materials in all non-structural parts. Like all new DENVER products KREA complies the Denver Eco Friendly system which aims to reduce energy consumption by 30%.

KREA will be presented to the WELCOME DAY event held in DENVER’s headquarter in Gualdicciolo (Rep. S. Marino) the 26th of March.

For more information please contact the company at 00378 (0549) 999688 or write to info@denver.sm

http://www.glassonweb.com/news/index/12723/

Tolland, CT – Precision Machining Technology Show 2011 will feature the latest in the line of powerful Mastercam machining software. Stop by booth # 1212 at the Greater Columbus Convention Center, Columbus, OH, April 19-21, for a look at the latest release, Mastercam X5, and a preview of the upcoming Mastercam Swiss Expert.

CNC Software has acquired well-respected Swiss machining software SylvieXpert. Developed in Switzerland for Swiss machines by experts in the Jura region of Switzerland where these machines were invented, we’ve been refining and adapting it. We will be previewing the 2011 release of Mastercam Swiss Expert at this show.

The company will be spotlighting the newly released Mastercam X5, including:

- Fast, aggressive, intelligent roughing

Mastercam’s new 3D surface high speed OptiRough toolpath is a new technique designed to remove large amounts of material quickly using its successful dynamic milling motion. Large, aggressive cuts are followed by fast, smaller up-cuts, safely delivering a fully roughed part faster than ever.

- Smart Hybrid Finishing

Hybrid finishing intelligently blends two efficient cutting techniques in a single toolpath. This new toolpath evaluates the model shape and smoothly switches between Constant Z cutting and Constant Scallop machining. The result is a dramatically finer finish with less work.

- Streamlined multiaxis machining

Mastercam’s multiaxis suite has new machining techniques and a new, easy, workflow-oriented interface. Mastercam lets you choose the basic type of work you’re doing using clear illustrations, and then gives you a clear, step-by-step process for defining how you’ll cut the part. Mastercam’s multiaxis machining also includes a new highly specialized interface for smooth, gouge-free engine head porting.

- New Dynamic Milling Techniques

Dynamic milling constantly adjusts the toolpath to ensure the most efficient cut possible and allows use of the entire tool flute length, often eliminating the need for multiple depth cuts. New dynamic milling techniques include Dynamic Rest Mill and Dynamic Contour. Dynamic Rest Mill helps ensure maximum tool efficiency during cleanup routines. Dynamic Contour uses an intelligent, efficient high speed contouring strategy to remove material along walls. It supports multi-passes and can optionally include finishing passes.

http://www.cadcamnews.in/2011/02/cnc-software-inc-showcases-mastercam-x5_16.html

Reid Supply Company has an exhaustive catalogue of industrial supplies, but no supplier can carry every conceivable piece of industrial equipment down to the individual component. This is why Reid Supply announces its own state-of-the-art precision tool components and machining company to create industrial products on demand for clients, via their sister company Total Quality Machining (TQM).

Industry demands sometimes call for modifying existing industrial parts. When trying to solve a problem, it is often better to rework existing parts rather than starting from scratch and designing and buying all new industrial products.

“Reid, through TQM, is able to fully customize many standard industrial parts that we have on-hand, as well as create new industrial products,” says John Carrier, President of Reid Supply Company. “This service is not offered by our competition and allows our customers to get exactly what they need.”

Reid Supply’s TQM machine shop staff employs high-end computer numerical control (CNC) programmable machining centers to provide their clients with the right solutions to their custom industrial equipment needs. With programmable CNC machining equipment, their vast library of CAD drawings acts as a virtual template for controlled and precise production, which is a necessary component of custom industrial equipment work. While there are plenty of craftsmen that can do amazing custom work on industrial supplies, programmable CNC tools provide reproducible accuracy and precision for both small and large size batch orders.

“If a client ever needs to re-order a custom job, all of the information remains on file and ready to be used to fulfill further orders,” says Carrier.

Custom work on industrial supplies is like a moving target. Sometimes a set of custom tooling balls is required, and other times a rework has to be done on entire systems. TQM works on both sized scales. They can create custom workholding solutions, manufacture non-standard size industrial supplies, and work all the way up to custom industrial equipment systems.

“Our TQM clients have business needs that range from the small to the very large, so we match our machining capabilities to those requirements, says Carrier. “Ultimately, all of our clients receive the same level of precision on industrial products whether they are components with very tight tolerances or a rework of an entire system.”

Reid Supply and Total Quality Machining subscribes to the ‘do it right the first time’ mentality in order to guarantee exceptional performance in all of their standard and custom industrial products.

http://www.pddnet.com/news-reid-announces-customized-industrial-products-021411/

Tormach, LLC, manufacturer of the PCNC 1100 personal CNC mill, is announcing their workshop dates for March and April of 2011. They will offer “CNC for Beginners” March 17th-18th, “CNC Fundamentals” April 26th-29th, and “SprutCAM 1-Day Training” April 26th.

The workshops are hands-on training and each course is designed for a different interest level.

“Tormach’s mission statement is to empower people who make things,” said Andy Grevstad, training coordinator. “Educational opportunities like CNC Fundamentals will help us to continue to meet that goal for our customers, regardless of CNC experience.”

CNC for Beginners is a 2 day workshop designed for those who are new or just getting started with CNC manufacturing. This workshop is hands-on. The goal of this workshop is for students to gain confidence in operating a CNC Machine and learn the basics of CAM and toolpath design.

CNC Fundamentals is a 3.5 day workshop designed as an immersion course in CNC for prototyping and custom manufacturing. This is a survey of the CNC process, from concept to cutting chips, with an emphasis on learning and building confidence. This workshop is hands-on. Each attendee will gain practical experience in CNC programming, machine control, and machining as they build a model Stirling engine. There will be significant emphasis on Computer-Aided Design and Manufacturing (CAD/CAM), advanced CNC control, and workholding techniques.

SprutCAM 1-Day Training provides attendees with basic knowledge to use SprutCAM for programming tool paths for a CNC mill. The class will focus will be on taking a design from 3D model to complete tool path creation, with special attention to configuring SprutCAM for your mill and tool library. Advanced Topics include 4th axis and lathe programming.

The workshops will be held in Waunakee, WI, just north of Madison. For a complete agenda and information on upcoming dates and how to sign up, visit www.tormach.com/workshops.

About Tormach
The people at Tormach are dedicated to delivering tools, accessories, and components of unprecedented value in the world of CNC and motion control. Whether you are involved in R&D, education, short-run production, or simply entrepreneurs with new ideas, Tormach products allow you to make what you need easier, quicker, and more affordable.

Tormach is headquartered in Waunakee, Wisconsin. For more information about ‘personal CNC’ mills and accessories, please visit www.tormach.com or contact Tormach directly at info@tormach.com

http://pr-usa.net/index.php?option=com_content&task=view&id=621978&Itemid=33

VERICUT 7.1 features significant enhancements to reduce the time required for manufacturing engineers to easily develop, analyze, inspect and document the CNC programming and machining process. Along with proactively adding new features, CGTech developers and engineers focused on addressing hundreds of customer-driven enhancements.

“VERICUT 7.1 builds on CGTech’s highly successful VERICUT 7.0 release, that contained over 700 customer requests delivered throughout 2010,” said CGTech Ltd managing Director, John Reed.  “Version 7.1 contains over 400 customer requests and further improvements to VERICUT’s user interaction, simulation capabilities & analysis, cutting tool creation, and CAD/CAM integration.”

VERICUT Product/Function Overview:
VERICUT is CNC machine simulation, verification and optimisation software that enables users to eliminate the process of manually proving-out NC programs. It reduces scrap loss and rework. The program also optimizes NC programs in order to both save time and produce higher quality surface finish. VERICUT simulates all types of CNC machine tools, including those from leading manufacturers such as Mazak, Makino, Matsuura, Hermle, DMG, Mori Seiki, Makino and Chiron. VERICUT runs standalone, but can also be integrated with leading CAM systems such as Dassault Systemes Catia, Siemens NX, Creo (Pro/E), MasterCAM, EdgeCAM, Delcam PowerMill and Open Mind Hypermill.

TOOL MANAGER
To further simplify creating a VERICUT tool library, CAD solid models of inserts and holders can be imported into VERICUT. The new feature added to the Tool Manager displays the CAD Geometry window that allows easy identification of which parts of the CAD model file corresponds with holders, cutters, or inserts. CATIA and STEP models are supported.

It is now possible to create and display coordinate systems in the Tool Manager. These coordinate systems can then be used to align tool components.

CAD MODEL ASSEMBLY
A new feature, Assembly, in the Open model file selection window enables the user to extract all individual components of a CAD assembly file and store them in their own model definitions. If Assembly is toggled “on” (checked) a separate model will be created for each component in the CAD model. When toggled “off” (unchecked) all components are used to create a single model. This feature supports STEP, CATIA, and Siemens NX model types.

VERICUT REVIEWER
The VERICUT Reviewer incorporates all the functionality of NC Review mode in a stand-alone viewer that does not use a VERICUT license. The Reviewer can play forward and backward while removing and replacing material. Error messages and NC program text is highlighted when a collision on the stock or fixture is selected. An NC program line display is optional. The user can rotate, pan and zoom just like normal VERICUT, and the cut stock can be measured using all the standard X-caliper tools. The “Reviewer” file can be saved at any point in a VERICUT session.

CUTTING CONDITIONS SHOWN
Cutting conditions are shown in the status display and available when stepping through the program using NC Program Review. The feature shows detailed information about the cutter’s engagement with material, including: axial depth, radial width, volume removal rate, chip thickness, maximum surface speed and contact area.
CNC PROCESS DOCUMENTATION
With the VERICUT report enhancements, users can preview and customize report templates to include features such as pictures and videos and links to files and websites. These reports have become increasingly valuable for VERICUT users to share CNC machining process information throughout their organisation and supply chains.

MACHINE SIMULATION
A new feature has been added for VERICUT collision checking: it is now possible to stop the simulation at an “exact” collision point between the machine components.  While simulating an NC block with the Stop At Collision box checked, VERICUT will stop in mid-motion at each collision point. Clicking the Step button continues simulation to the next collision point (or to the end of the motion if no other collisions exist).

ADDITIONAL ENHANCEMENTS:

• Project tree enhancements including a new UNDO function
• The Pro/E interface has been enhanced to improve creation of parametric, sketch, and solid tools.
• Helical milling material removal is enhanced by creating a “true helix” motion type.
• Material removal for general gear cutting and broaching operations is supported.
• Simulation of back spot-facing tools is now supported.
• Diameter value is added to hole measurement information in X-Caliper.
• VERICUT now supports a full range of six-axis robots to simulate machining, waterjet trimming, fibre-placement, drilling and fastener insertion.
• A general linkage component is added to allow the connection of two driven components with a slaved linkage.
• The ability to output a NC program, of a different format than the input program, is added to base VERICUT functionality. The method for re-formatting the program is user-configurable.
• All popular controls continue to be enhanced with new advanced features: Siemens 840D, Fanuc 30’s, Heidenhain, Okuma OSP, Mazak Matrix.

About CGTech
Headquartered in Irvine, California CGTech specializes in numerical control (NC/CNC) simulation, verification, optimization and analysis software technology for manufacturing. Since 1988 CGTech’s product, VERICUT® software, has become the industry standard for simulating CNC machining in order to detect errors, potential collisions or areas of inefficiency. With offices worldwide, VERICUT software is used by companies of all sizes, universities and government agencies. For more information, visit the CGTech website at www.cgtech.com

http://www10.mcadcafe.com/nbc/articles/1/922976/CGTech-announces-next-major-version-VERICUT-CNC-machine-simulation-optimisation-software-Version-7.1