The NC program programming software at the production site can quickly complete the preparation of the processing program required by the user and complete the processing of prototypes. This, in turn, plays a decisive role in market competition. Who can provide high-quality samples in a short period of time, who can quickly get orders again.
CNC machines equipped with high-performance CNC programming software can replace a CNC programming department. Helmut Kottmaier CNC turning and milling technology company is a good example. The company's employees must master the use of programming software in order to be able to quickly complete the preparation of part processing programs. Due to the skills of its employees, the company has become an expert in the rapid and precise processing of stainless steel parts. Their daily production and processing products are hard-to-cut and heat-resistant metal materials, such as those needed to make three-way catalytic converters. Although they are a professional manufacturer, low cost, high quality and fast delivery are still important competitive factors. Therefore, they will also work overtime and work overnight if necessary.
CNC machine programming software displays parts to workers at Kottmaier and displays each step of the process on the display
Universal programming software
According to Helmut Kottmaier's experience, the use of a department that centrally compiles numerically controlled machining programs to uniformly compile the weaving structure of all CNC machining programs has not been able to adapt to the extremely urgent needs of sample parts and trial production processes during the delivery period. Instead, they installed a set of programming software on all CNC machine tools in the factory. The transformation of this programming technology has great benefits. Multiple programming stations can be used simultaneously; no new hardware needs to be added; nor will the size of the auxiliary office be increased.
This Munich-based processing factory uses Shop-Mill and Shop-Turn CNC programming software developed and designed by Siemens. In the process of programming a part, the software's graphical assisted function is of great help. At the same time, it can accurately reflect the whole operation of machine tool operation and workpiece processing. It intuitively provides the operator with program control and control of the CNC operation of the machine tool. So that each machine operator can immediately use the programming software to prepare the machining program of the CNC machine tool after a short period of familiarity with the software.
The end result is that Kottmaier can rapidly complete the programming of 3+2 axis asymmetrical workpiece machining without professional CAD programming technicians.
Image support programming method saves programming time
The image programming method is very fast for writing part programs. For example, a threading cycle can take only a few seconds to write (see Figure 1); it takes at least a few minutes. Therefore, in the Kottmaier company, most employees use the image-supported programming method when writing a part's NC machining program. The traditional ISO statement-style programming method can also be realized in Shop-Mill and Shop-Turn. The operator can compile the NC machining program at any time in combination with the ISO NC command code used in the software. At any stage of the machining program, it is easy to convert between the image programming interface and the ISO code programming interface. Therefore, the instruction instruction programming knowledge and skills that the operator has already mastered can still be used, and it can also be extended in the application of the new image programming technology.
Fig. 1 Even if the parts are extremely complex and require high precision, Kottmaier's employees can independently write the processing program with the help of graphic programming tools, contour programming tools, and a large number of practical machining cycles.
In Shop-Mill and Shop-Turn two kinds of CNC car, milling programming software, the operating principle of the software is the same. Therefore, the operator of the digital controlled vehicle can easily grasp the programming method of the numerically controlled milling, and the operator of the numerically controlled milling can quickly learn to write the processing program of the numerical control car. Therefore, Kottmaier's employees do not have the distinction between cars and milling, that is, they can operate CNC cars and can also operate CNC milling.
In addition to automotive companies and suppliers, robot manufacturers are also important customers of this processing company, such as Kuka. Therefore, many of their products are shaped complex shaped parts, such as the transmission housing and the transmission cover. Kuka often encounters trial production or single-piece production in the production and development of robots, and the demand is often as short as possible. At this point, using the contour programming function of Shop-Mill and Shop-Turn, you can quickly complete the preparation of CNC machining programs in accordance with the design drawings. Samples, pre-production products, and mass-produced products produced by Kottmaier for Kuka are generally stainless steel parts that can guarantee the high performance of robots. When these robots are used in food production companies, such as bread baking robots and slaughter robots, as well as robots used in pharmaceutical manufacturing companies, they do not allow any lubricant on their outer surfaces. Therefore, in the processing of these parts, even the parts with a large volume and area are processed, the fitting tolerance is often only 0.02mm, and the required tolerance class is H6. Trial production products will eventually undergo rigorous testing at the user. In order to ensure that the parts produced by CNC machine tools can pass these rigorous inspections, Siemens Shop Programming Software not only has a comfortable operation interface, but also provides a powerful guarantee for the extremely high processing accuracy and economy.
Pre-machined holes in the workpiece
The programming software can also complete the production and processing of specified workpieces based on local drawings. Sometimes, the user provides parts that have been partially machined, providing holes, threads, or milled profiles that need to be machined on such semi-finished parts, but there is no complete work piece drawing. In this case, the adjustment function in the programming software fully shows its superiority. If the position of the reference hole is accurately determined, it is even possible to determine the position of the reference hole in the imaginary space surface. When programming needs to modify and supplement the NC program according to the contour of the part, the contour editing function in the Shop software can be used to implement the existing and detected semi-finished workpiece data simply and quickly.
Figure 2 In order to facilitate the application of other machine tools, Siemens 840D solution line allows the transmission of data and programs through the U disk
The intelligent simulation function, including collision checking of workpieces and tools, gives the machine operator a good opportunity to observe the results of program processing during the job preparation. With the help of simulation functions, errors in NC programs can be found in a timely manner, and this ability to find problems in a timely manner is particularly important in the continued processing of semi-finished products. Because the waste products appearing in the subsequent processing of semi-finished products are not only more expensive, but also damage the user's reputation and reputation.
The CNC machining program written and simulated by the programming software has a very high process reliability, and can even make the CNC machine tool automatically complete all the processing tasks in an unattended situation. Therefore, any part of the Kottmaier company that has a long processing time starts only when it is about to leave work, so that the NC machine tool can complete the production of the workpiece without being on duty.
Based on years of experience using Shop-Mill and Shop-Turn CNC software, Kottmaier also installed the Shop-Turn software system in the newly purchased Spinner lathe. The machine's control system uses the latest Sinumerik 840D solution line system from the Siemens family. The operator can quickly grasp the operation and use of this system. In this new control system, the operator interface is not much different from the Sinumerik CNC operator interface. However, the electrical wiring of this new type of control system is not only in the machine's electrical control cabinet, but also greatly simplified in the console to make it more concise. This simplification facilitates fault diagnosis and maintenance of the CNC equipment. The USB interface on the front panel can be used to easily copy and transfer NC machining programs. It is only necessary to write a program to process the same on different machine tools. Artifacts, or to achieve data classification management of the PC (see Figure 2).
Profit in a very small profit space
Shop-Mill and Shop-Turn programming software not only contribute to the production of individual parts and small batch production, but also very popular in mass production. With this software, the individual advantages of each CNC machine can be combined to optimize the mass production process. For example, through the clever use of Shop-Turn CNC turning software, milling tasks that used to be completed in five passes can now be turned on unattended in just one setup. And it is using "bars" to complete all the cutting. The bar material required for the CNC lathe is loaded by the automatic feeding device, and the processed workpiece can be simply cut off.
Fig. 3 Milling tasks that used to be completed five times in the past can now be carried out unattended with one setup
According to Mr. Kottmaier, turning and milling complex machining techniques are often the fastest alternative machining solutions for complex turning parts that require multiple tools for machining. For example, machining a transmission cover often requires the use of 32 different tools. This number of tools exceeds the number of tools that can be accommodated in most CNC lathe tool magazines, and the numerically-controlled milling tool magazine contains significantly more tools. If all the machining is done on a lathe, the tool must be replaced by hand. If the milling, drilling and tapping operations are concentrated on a CNC milling machine, it will be much faster than a CNC lathe. . Although one setup was added, the workpiece processing speed and the entire production cycle were significantly improved (see Figure 3).
Secondary setting requires simple adjustment
With the help of the programming software adjustment function, it is possible to quickly and easily complete the secondary setting when changing the car and milling process. On the other hand, the Shop-Mill software system can also acquire geometric contour data of complex turning parts as well as Shop-Turn. In terms of the complexity of the workpiece, there is almost no difference in the recognition ability of the two softwares. Thanks to the balance compensation of the Sinumerik control system, round-grooving tools can also be milled with a high-precision fit. Therefore, it is often the case that typical turning parts complete all the machining tasks on CNC milling.
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