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Power of VoluMill

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  1. 1. Maximizing Output and EfficiencyA unique perspective on the challenges manufacturers face in the coming decade and how to overcome them to maximize profitability Edsel Vaz Country Manager
  2. 2. Confidential
  3. 3. Charles LindbergOn June 11, 1927, Charles Lindberg crossed the Atlantic in hiscustom-built plane, “The Spirit of St. Louis”. The craft was strippedto the bare bones and modified to carry 425 gallons of fuel, enoughfor his non-stop journey.He flew for 34 hours and covered 3610 miles. Thus, he used .11gallons of fuel per mile! (or 8.49 miles per gallon!) Confidential
  4. 4. Debuting in 1969, the Concorde could take 100 passengers across the Atlantic in 2 hours consuming 6 gallons of fuel per mile or 6407 gallons per hour. Confidential
  5. 5. TECHNOLOGY... Make it faster… Confidential
  6. 6. The Boeing 747-400 can carry 467 people across the Atlantic in about 6hours at 646 MPH burning 5 gallons of fuel per mile. The 747 family has carried half the worlds population 42 billion nautical miles. Confidential
  7. 7. CHANGES… Make it more reliable and economical…Balance speed with the lowest cost to meet customer demand to ensure profitability… Confidential
  8. 8. And now, the Airbus A380 holds the record as the largest airliner in theworld with a capacity to carry 850 passengers half way around the globewhile consuming 10 gallons of fuel per mile. It too can cross the Atlantic in about 6 hours despite it’s size! Confidential
  9. 9. EVERYTHING… …We do must meet the changing demands of new Economic and Market Challenges…You’ve just seen four approaches to solving the same problem, how the demands of the market have changed and how one industry has changed to meet theses demands… Confidential
  10. 10. TECHNOLOGY CHANGES EVERYTHING! What role will technology play as the demands of your marketincrease and your shop evolves to meet the challenges of the future? Confidential
  11. 11. AIRLINE INDUSTRY PROFITABILITY IS MEASURED BY…• Equipment uptime• Passenger seat/mile cost• Industry compliance• Reduced costs and overhead Confidential
  12. 12. AND NOW… THE BIGGER PICTURE• An A380 uses slightly more fuel per passenger, but looking ahead, Airlines must also meet the added challenges of airport and aerospace congestion. The infrastructure can only handle so many planes (slots) and it’s FULL!• The challenge becomes increasing passenger “through-put” and the A380 carries 850 passengers in a single “slot”, and slots cost money!• Just like your challenge is increasing part through-put through your existing CNC machines and shop floor space, which are also limited• It is the sum of your technology that will overcome that challenge, not just any one aspect Confidential
  13. 13. IT DOESN’T MATTER WHICH INDUSTRY YOU’RE IN…• Survival depends on understanding profit and loss• Embracing new ideas and technology gives us the competitive edge• Underestimating our weaknesses can be fatal• Change is a constant factor, so is the need to improve our processes and product• When faced with a challenge, we better see it coming and find a way to overcome it! Confidential
  14. 14. YOUR PROFITABILITY IS MEASURED BY…• Machine uptime• Material removal rate• Part compliance• Reduced costs and overheadMachine Simulation Plunge Rough Confidential
  15. 15. YOUR PROFITABILITY IS MEASURED BY…• Machine uptime• Material removal rate• Part compliance – Machine directly from native CAD models to reduce programming errors• Reduced costs and overhead – Increased tool life – Reduced machine costs – Increased ROI on machines – Reduced labor costs Confidential
  16. 16. YOUR PROFITABILITY IS MEASURED BY…• Machine uptime• Material removal rate• Part compliance• Reduced costs and overheadWe are going to focus on these two key areas where GibbsCAMcan optimize your productivity and profitability… Confidential
  17. 17. WHAT IS• It is a performance enhancement for GibbsCAM• It is a toolpath optimization geared towards maximum material removal rate• It’s primary focus is optimized roughing• It’s objectives are balanced high-volume material removal rate, optimizing tool life and fully exploiting a machine tool’s capabilities Confidential
  18. 18. Look at it like bolting a supercharger on a Corvette® Z06! … only easier, cheaper and with more bang for the buck! SuperchargerCorvette C6 Z06 Confidential
  19. 19. Look at it like bolting a supercharger on a Corvette® Z06!… only easier, cheaper and with more bang for the buck! Let’s look at some statistics…• Stock Z06 • Supercharged Z06• 505 H.P. • 660 H.P.• 0-60 – 3.4 seconds • 0-60 – 3.2 seconds• Quarter mile – 11.57 seconds • Quarter mile – 10.5 seconds • Upgrade cost $6,000-$10,000 • Installation time: A good day or so • % results increase – 7% • Increase in profitability – 0! Confidential
  20. 20. Now let’s compare this to upgrading your GibbsCAM software by adding totally integrated VoluMill: • No tools required • Installs in seconds • Totally integrated • Cycle-time reductions 40-60% • Upgrade cost (existing GibbsCAM customer): $1,500 - $2,500 • No added skills required • Increase in profitability – Dramatic! Confidential
  21. 21. MY CAM TOOLPATH SEEMS FINE. HOW CAN IT BE ANY BETTER?Let’s discuss some factors that indicate there could be room for improvement in your roughing processes Confidential
  22. 22. 5 SIGNS THAT YOUR ROUGHING STRATEGY HAS ROOM FOR IMPROVEMENT:• Premature tool wear, limited tool life, tool breakage• Vibration or inconsistent sounds when tool enters cuts, corners, or changes direction• The need for increased rigidity in fixturing or part shifting• Spiral swirling on wall finishes or spiral stepping on floors• The urge to have a nap while watching your tool cut Confidential or other remark
  23. 23. CONVENTIONAL TOOLPATH CALCULATIONSa • Traditionally, area removal toolpaths are calculated by working from a given shape(s) and calculating offsets inside-out or outside-in • This has been the industry standard for years and is the approach commonly applied in most toolpaths of this type by most CAM systems on the market today • It gets the job done and does allow for a lot of versatility in tool application • It has been a good solution for most applications Confidential or other remark
  24. 24. CHALLENGES PRESENTED BY OFFSET TOOLPATHa Confidential or other remark
  25. 25. CHALLENGES PRESENTED BY OFFSET TOOLPATHa • Sharp corners and radical directional changes increase tool loading • Moving between cuts increases tool loading • Tool performance is limited by overloading in red areas • Cut depth, RPM and feed needs to be reduced to survive red areas • Material removal rate in grey areas becomes limited by red areas • The result is a compromise in cutting parameters for the entire operation to ensure cutter survival and a reasonable lifespan Confidential or other remark
  26. 26. DEFINING PRODUCTIVITY AND EFFICIENCY• Productivity and efficiency means maximum output with lowest costs… make more parts in less time, giving you the most profitability!• Profitability is getting the maximum return from your capital investments and high-dollar consumables• Your machine tools and facility that supports them are your largest capital investments• Labor costs to support each hour your facility is operational are a significant overhead• Perishable cutting tools are one of your greatest consumable expenses Confidential or other remark
  27. 27. YOU INCURE COSTS FOR EVERY HOUR YOU OWN A MACHINE AND EVERY CUTTING TOOL YOU BUY… YET:• CNC machines on average operate at 50% of their true capacity, and that’s during UPTIME!• The lifespan of most cutting tools ends prematurely due to abnormal wear to a small percentage of the effective cutting edge or damage other than wear from abuse (chipping, pitting, burning) Confidential or other remark
  28. 28. END MILL WEAR CONDITIONS• Localized depth of cut wear – Note depth of cut wear• Catastrophic Shock Wear (vibration, chatter, packing)• Typical normal wear Confidential
  29. 29. IN A PERFECT MACHINING WORLD:• Machining would be consistent, uninterrupted and vibration free!• The entire cutting edge of a tool or insert would be utilized• Both machine tool and cutting tool technology would be operating at maximum efficiency Confidential
  30. 30. A SNEAK PEAK INTO THEPERFECT WORLD OF OPTIMIZED MATERIAL REMOVAL:• Video courtesy of Mikael Bagge, Fruktus AB Sweden Confidential
  32. 32. TITANIUM, .500 5-FLUTE:Before VoluMill After VoluMill• ADOC: 0.315 (Axial Depth of Cut) • ADOC: 0.600• RDOC: 0.220 (Radial Depth of • RDOC: 0.035 Cut) • RPM: 3,056• RPM: 1,225 • IPM: 100• IPM: 6.25 • Cycle Time: 30:00• Cycle Time: 80:00 • Parts per Tool: 40• Parts per Tool: 4 • CIM MRR: 2.10• CIM MRR: 0.433 (Cubic Inch/P/Minute Metal Removal Rate) Confidential
  33. 33. WHAT THE CUSTOMER SAID:“The results were so dramatic that the one order paid forthe software. It’s been all profit after that.” “Common sense tells me it’ssaving wear and tear on my machines.” “It did more than I expected it would do.” Confidential
  34. 34. PERFORMANCE TOOL AND DIE A2 TOOL STEEL: Before VoluMill After VoluMill • 2” insert shell mill & .500 4- • .500 5-flute flute • ADOC: 1.00 • ADOC: .15 / 1.00 • RDOC: 0.030 • RDOC: 1.25 / 0.02 • RPM: 12,000 • RPM: 700 / 3,000 • IPM: 200 • IPM: 35 / 30 • Cycle Time: • Cycle Time: 22:36 07:20 Confidential
  35. 35. WHAT THE CUSTOMER SAID:“We realized a 208% increase in productivity.” “It’s paid for itself in no time.” “The benefits exceeded our expectations.” - Confidential
  36. 36. OPTIMA MANUFACTURING718 INCONEL - .375 4-FLUTE: Before VoluMill After VoluMill • ADOC: .125 • ADOC: 5.00 • RDOC: .010 • RDOC: 0.020 • RPM: 1,000 • RPM: 1,000 • IPM: 8 • IPM: 12 • Cycle Time: • Cycle Time: 40:00 17:00 • Part per Tool: 1 • Parts per Tool: 2 • CIM MRR: .01 • CIM MRR: .12 Confidential
  37. 37. WHAT THE CUSTOMER SAID:“The new toolpath removes the material much faster while putting farless stress on our cutters and machines.” “Not only is the cycle time dramatically shorter, but the extended tool life is impressive.” “Management was easily convinced with such a quickROI.” - Jonathan Wang, Optima Manufacturing Confidential
  38. 38. Typical Toolpaths• Created by offsetting boundary geometry• Tools encounter excess material: • With the initial cut • When connecting from one cut to the next • When feeding past the turning point of the previous cut • When feeding into new areas• Increased MRRs, increased loads
  39. 39. Following Offsets
  40. 40. Initial Cut
  41. 41. Initial Cut
  42. 42. Initial Cut
  43. 43. Between Cuts
  44. 44. Between Cuts
  45. 45. As Desired
  46. 46. Increasing Load
  47. 47. Into Corners
  48. 48. Cut Width• Makes it easy to generate toolpaths• Establishes poor machining conditions• Requires machine tools and cutting tools to operate under unreasonable circumstances• Causes load fluctuations• Causes variations in MRRs
  49. 49. The Result?• Machine tools and cutting tools are either abused or under utilized – they never get to run in their sweet zones• Toolpaths are the weak link in the milling chain of events• Milling productivity is far below its current potential
  50. 50. Tail Wags Dog• Sharp corners increase tool load• Moving between cuts increases tool load• Tools abused in red areas• Parameters must be set to survive red areas• Tools under utilized in gray areas• Parameters inefficient for majority of path
  51. 51. The Solution?• Better toolpaths; toolpaths that:• Enable machine tools and cutting tools to run to their full potential• Toolpaths that are not the weak link in the milling chain of events• Make the Cut Width parameter a cause-and- effect parameter
  52. 52. ™ V OLU M ILL• Patent-pending toolpath technology• From the words volume and milling: manages the rate of material removal for even machining loads• Uses the Cut Width parameter to control the width of cut on the machine• Enables machine tools and cutting tools to operate under ideal conditions
  53. 53. Ideal Conditions
  54. 54. Aerospace Job Shop 625 Inconel, .500 5-Flute• Before VoluMill • With VoluMill – 0.250 ADOC – 0.600 ADOC – 0.400 RDOC – 0.070 RDOC – 400 RPM – 3,000 RPM – 2 IPM – 30 IPM – 00:35:00 Cycle Time – 00:07:00 Cycle Time – 3 Parts per Tool – 12 Parts per Tool – Tool cost = $15/Part – Tool Cost = $3.75/Part
  55. 55. Motivation “Manufacturers want to increaseproductivity, but without capital expenses or labor increases.”
  56. 56. Capacity• Manufacturers have plenty of untapped productivity capacity – Your machine tools are capable of significantly higher productivity levels at reduced costs – Your cutting tools can remove material much faster, last much longer, and be used completely• But traditional toolpaths render this capacity potential unreachable
  57. 57. Why VoluMill• Adding better toolpaths to your operation:• Is inexpensive• Is simple – be up and running in minutes• Is unobtrusive – runs inside GibbsCAM• Has an immediate impact – quick ROI
  58. 58. Questions?
  59. 59. HOW ARE CUSTOMERS USING GIBBSCAM WITH VOLUMILL ACHIEVING THESE RESULTSa • They experienced an instant gain of 30-60% in productivity • They benefited from an increase of tool-life of 50% or much more • They saw an immediate return on investment Confidential
  61. 61. IT SOUNDS LIKE MAGIC, BUT IT’S REALLY QUITE SIMPLE…a • VoluMill creates a more uniform toolpath that allows a cutting tool to maintain optimal cutting conditions on it’s depth of cut and radial in-feeds Confidential
  62. 62. SAME CNC MACHINES, SAME CAM SOFTWARE…a • No new skills or retraining required • Same postprocessors, no post editing • Savings begin on the first job programmed! Confidential
  63. 63. LET’S HAVE A CLOSER LOOK AT FORa Confidential
  64. 64. IT’S QUICK, EASY, AND PAINLESS!• Supports Mill, Mill/Turn, and Multi-Tasking-Machines (MTM)• Totally integrated with GibbsCAM Machine Simulation to further reduce machine downtime and increase profitability• No special post processors or post editing required Confidential
  65. 65. THE END… Of the presentation… THE BEGINNING…Of a new outlook on more efficient material removal… You have seen what VoluMill CAN do, and you’ve seen what it HAS done for other companies, so start saving today and try it at your shop for FREE for 30 days! Confidential
  66. 66. Thank you for your time.We know it is VALUABLE!