Success Story
The company are expert in developing CAM toolpaths that encapsulate the optimal material removal strategies and produce the least expensive, conforming component for the process. They verify that the trajectory of the toolpath will avoid machine tool collisions, part gouging or undesired excess material by utilising industry-leading CAM software.
Sometimes, this process requires adaptation, depending on client’s specialist requirements. This is the story of how they addressed one such requirement, with the help of Symetri to bring their post-processor capabilities in line with a sensitive product requirement—in the field of Life Sciences—where the even the tiniest variance in hole-piercing is unacceptable.
Upgrade the post-processor to automate the tapping cycle
The functionality of the post-processor was not as comprehensive as it needed to be for the company's requirements. Symetri upgraded the post-processor to the new AMPPU format (.pmoptz) allowing for all necessary post-processor functionality and, more significantly for the company enabling automation of the tapping cycle.
Address the hardware
In terms of machine functionality—the hardware side of the problem—Symetri recommended a smarter way of taping the previously drilled holes; by incorporating a Floating Tap Collet. This device compensates for any remaining spindle movement that occurs when the tapping operation depth is achieved and the machine stop is activated and reversed to remove the tap from the hole.
Upgrade the post-processor, fine-tune the functionality, deliver accuracy every time
Symetri looked at the company's entire tapping process from both a software and a hardware perspective. The first was to look at the existing post-processor, Ductpost; which relied on an old format (.opt) with the added complication that it did not support a tapping cycle for cutting internal threads. The functionality of the CNC machine itself also offered a solution to the hand-tapping problem.
The solution was:
Wastage “drastically reduced” from 50% to less than 5%
Symetri embarked on a series of tests to make sure that the new file format for the post-processor was fully aligned with the machine kinematics.
The result was a total improvement in their processes. They drastically reduced wastage to around five per cent. This gave the company back the time they had previously had to spend on starting afresh each time a door was rejected and led to faster turnaround times and improvement in our profitability.
Project summary
Duration & delivery
Autodesk solutions
Services provided
Customer industry
UK Company Achieves Greater Accuracy, Improved Quality, and a 90% Reduction in Wastage with Symetri’s Post-Processor Upgrade
Plastic Solutions identified the following challenges to address:Reduce wastage resulting from the hand-finished rendering necessary by using an old version of post-processor software.Minimise client rejection rate and associated costs of re-supplying replacement product.Improve quality.Accelerate lead times.
Symetri’s Autodesk Fusion 360 Training Consolidates Skills for Manufacturing R&D Support at University of Aberdeen’s Engineering Workshop
Upskill the whole engineering team in Fusion 360.Aberdeen University had issues with the software they were using to programme their 3-axis CNC machine. They asked the machine manufacturer HAAS what they could do to get around the problems they were having and they recommended Autodesk Fusion 360.The team saw immediate improvements apart from two issues that arose. Within an experienced engineering team that is very proficient the missing link was that they were all using the software in a different way and it became clear they needed consistency. The other issue was that despite having moved to Fusion 360 the team were still using manual machining techniques."In a way, we were all in our comfort zone with manual milling, but we knew we could gain far higher degrees of accuracy and dependability if we used Fusion 360 for Milling," says Gavin McFarlane, Senior Mechanical Technician.They did some research on who could provide the training and found Autodesk Solution Provider Symetri.Challenges they faced included:Reduce wastage resulting from the hand finished rendered necessary by using old version of post-processor softwareMinimise client rejection rate and associated costs of resupplying replacement productsImprove qualityAccelerate lead times
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