The integration of CAD/CAM software to a machine tool can increase confidence when it comes to machining complex parts. When these systems are paired with a machine’s control, shops gain valuable real-time data at the machine and the ability to generate more accurate part program simulations, which, in turn, increases a shop’s odds of producing a good first part, thus minimizing prove-out time.
When shops run these simulations, they gain confidence because the simulation uses all the machine’s data as provided by the machine tool OEM.
As a result, what happens in the simulation will happen exactly the same way on the machine—as long as the tool data is accurate.
Nowhere is this assurance more important than when running complex medical parts. Shops have invested considerable expense in machine tools that are needed to run equally expensive parts, so the program must be right.
When it comes to optimizing part program simulations, OEMs have tried to shoehorn CAM systems into machine controls for decades. But the results have seen little success, mainly for two reasons: machine control computers lack the power; and shops would rather not have operators or programmers spend a long time working at a machine’s control on the shop floor.
More powerful machine controls are possible, but doing so would increase cost considerably. For example, a $6,000 computer will run CAM, but a huge amount of customization is needed when you try to incorporate it into a machine control that can skyrocket costs to over $30,000. The machine’s control has to fit the NC side as well as the PC side, and they must work together—a balance that requires expensive custom hardware.
While cloud-based CAM on a machine is in the works, it currently makes more sense to provide CAM systems with some type of seamless integration to a machine’s control.
Mazak provides an application programming interface that allows CAM software to seamlessly access data from its MAZATROL Smooth machine controls. The software uses that data to generate extremely accurate part program simulations. Such an accomplishment wasn’t possible until the development of more robust interfaces.
To make the interface effective, Mazak essentially provides all the same information that is used in its machines to CAD/CAM suppliers. They have the software engineers, time, and computing power to make simulation graphics sharper and more precise, as well as very realistic, then tie them directly into their CAM system. Moreover, the interface keeps machine controls affordable.
The connection between the CAM software and the machine control allows shops to produce programs that take into consideration the specifics of the machine being used and how it operates—its capabilities, kinematics, tooling, and range limits. Without exact data, programmers often guesstimate a machine’s true capabilities.
For example, a programmer will select the necessary tooling and produce a part program. The program is then loaded into the machine. But what if a 4.00” diameter tool was specified in the program when the tool in the machine actually measures 3.99” in diameter? Yes, the program would produce the part, but it would be much more accurate if the CAM program knew the exact tool size. The interface between CAM systems and machine controls allows shops to work in an actual world with real data.
This removes a lot of the guesswork in programming a machine tool. And it gives shops the confidence to push the cycle start button, know a program will run exactly as it did in simulation, and produce a good part the first time. This is especially beneficial when running complex five-axis parts or when operators are unable to see inside the machine to watch a part run.
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