Software helps create flexible part set-ups and reduce production cycle time
Alp Aviation, (Eskisehir, Turkey), uses on-machine probing capabilities aided by Reinshaw’s Productivity+ software to reduce production cycle times by 50 percent.
Implementation of Renishaw's Productivity+ software enables Alp to create and test routines in a CAM environment for Renishaw probes fitted to all 50 of their machining centers. Progressive application of machine probing creates fast, easy set-ups, simple fixtures, in-process checks and compensations before final machining passes.
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"We looked at the whole production cycle time and in some cases were able to reduce it by up to 50 percent," says Cenk Akin, Engineering Team Leader at Alp.
"The Productivity+ software and Renishaw's part-setting probes have made this possible. The benefits not only include time and cost savings; we can also trust the process since any chance of machine operator error has been removed. Process repeatability has improved and we've achieved a higher level of gauge R&R results by using probes with less than one micron repeatability."
When a new part is introduced at Alp, a production engineer is assigned to that part and is responsible for developing all the processes throughout the production cycle. CAD data is sent to the engineer by the customer and a cutting process – including cutting tool selection – is prepared using a Unigraphics CAM system. The NC part program that Unigraphics produces is then loaded into the Renishaw Productivity+ package where the engineer adds probing cycles.
The probing cycle runs as a simulation on the PC, picking up on any errors before it reaches the machine tool.
"Productivity+ makes it much easier to prove out the process before going on the machine," says Akin.
"If the machine is being used to test processes rather than producing saleable parts, we are losing money."
The finished program is loaded onto the appropriate machine via the DNC system and one test part is produced to verify the machining and probing program before full production begins.
Productivity+ was purchased in July 2007 to reduce process development time. Alp's working environment is virtually paperless and highly automated, so they couldn't afford to manually program the probing routines, notes Akin.
Productivity+ uses a graphical user interface (GUI) to provide an extremely user-friendly programming environment. Alp engineers simply pick features from the CAD model, or choose parameters from dialog boxes, to define the program. Prismatic features can be selected from CAD with a single click and capture.
Intuitive menus remove the need for knowledge of probing macro commands, which vary by machine controller and are a time-consuming way to produce routines.
When the program is complete, the required post processor is selected and the output is automatically generated, ready for loading directly into the machine.
Alp has used Renishaw part-setting spindle-mounted probes for years, but mostly for set-up. All new machines are delivered with probe systems fitted. Prior to the Renishaw probes, the operator would manually align the part on the table, or they would have to order a special fixture made for every variation of component. Now, operators use simple clamping, and machines are programmed to use the probe to locate the part.
The drive to speed and simplify set-up is important to Alp in reducing production cycle times and maximizing flexibility on parts that have many variants. While some batches can run on a machine for a year, other machines change batches two or three times a day with only a few components in each batch. Between using Renishaw probing to shorten setups and pallet changing systems to load components while the previous part is being machined, Alp is close to reaching their goal of zero set-up times.
Next, probing is used for process control to check every part before finishing cuts are made.The probing routines automatically update machine offsets. Previously, this would rely on the operator and the likelihood of errors was much higher.
Finally, Productivity+-generated programs allow the probe to inspect the part on the machine once cutting is finished. This eliminates post-process quality checks for faster part throughput and reduced Work in Process inventory.
"This technology – the Renishaw probe systems and Productivity+ software – are critical components to our long-term business plan," says Senay I'dil, General Manager of Alp.
"We view it as a relatively low cost investment that is essential to run our machines as efficiently as possible."
For more information visit www.renishaw.com