With the globalization of the mold industry, Japanese companies are working to further improve their technical capabilities and work.
In 2005, Sankyo Co., Ltd. introduced CADCEUS 'DieStacker, a CAM for processing structural parts, in 2005 to improve the data processing rate of structural parts. Realization of data conversion in the processing of structural parts, achieving a data output rate of 60%.
In the meantime, with the advancement of data processing for structural part processing, SOLID design has become the mainstream from 2D drawing design, and it has been required to further increase the data output rate of structural part processing.
From 2014, we shifted to CADmeister's CAM-STRUCTURE, an automatic CAM for machining structural parts. Based on a knowledge database that digitized the company's machining know-how, the company designed automatic machining such as machining procedures, tools, and machining conditions, and worked to reduce the man-hours required to create structural part machining data. Percentages have been achieved.
This time, we will introduce our efforts to introduce “CAM-STRUCTURE”.
Sankyo Co., Ltd.
Hyogo Prefecture Kobe City Nagao Town Tatehara character upper middle 41
Manufacturing Department CAD / CAM Division
Chief Nishio Tsuiware like (left)
Ohashi Atsushi耶like (right)
Sankyo Co., Ltd. was founded in 1960 as a stamping die manufacturer, and designs, manufactures and maintains stamping dies related to automobiles, construction machinery, and agricultural machinery. It has a 2000t mechanical press and 3D laser processing equipment, and handles a wide range of dies from outer parts to inner parts for automotive parts. In particular, it has a reputation for designing and manufacturing deep drawing dies, and also conducts die manufacturing and component evaluation using molding analysis to meet customer needs. It has an order record of 128 types per year (average 4.9t).
・ Many man-hours were spent on preparation before NC data creation, and there were many situations where data output was not in time for the processing schedule.
・ Since unmanned machining in 5-axis machining was not possible, 5-axis machining of structural parts was always performed by man.
・ Man-hours for preparation before NC data creation were reduced by 50%. The amount of data output has increased, and it has become possible to meet the processing schedule.
・ The man-hours required to create NC data for mirror properties was reduced by 40%.
・ Realized unmanned 5-axis machining.
-Data was also created for the parts that were manually processed, achieving a data output rate of 90%.
As SOLID design becomes mainstream, the required data output of the structural part has doubled.
Choosing an automatic CAM for processing new structural parts and trying to reduce man-hours by automating CAM work!
In structural part machining, workers at the site have long worked by manually operating machines while looking at 2D drawings and dimensional drawings.
However, unmanned machining at night cannot be ensured only by shape machining, and there are many machining machines that stop machining at night. In 2005, with the introduction of CADEUS's CAM “DieStacker” for structural part processing, data processing of structural parts was realized. The data output rate could be raised to 60%. However, with DieStacker, it took a lot of man-hours to prepare for data creation and SOLID editing work, so it was difficult to further increase the data output. In 2014, UEL proposed a new automatic CAM “CAM-STRUCTURE” for 5-axis machining that could handle 5-axis machining while considering further work improvements.
"For us who create machining data, the new system is a huge burden. However, it was difficult to significantly increase the data output of the structural part with the existing system. Will continue to develop further in the future, aiming to accelerate the automation of CAM work. ”I felt the future of the word and decided to introduce it," says Nishio.
Starting work on a new system CAM-STRUCTURE from November 2014. Preparations were made in parallel while performing normal work with DieStacker, and test processing was carried out in April 2015. Currently, CAM-STRUCTURE alone is in full-scale operation with two systems.
Mr. Ohashi, who was responsible for the start-up work, said, "It was difficult to understand the mechanism of the new system, but the operability was kinder and easier than DieStacker. The registration of the knowledge database first migrated the DieStacker registration contents After that, CAM-STRUCTURE not only realized unmanned 5-axis machining, but also used DieStacker's key groove, which was manually machined. For parts other than 5-axis machining, such as chamfering, we worked with UEL's Support SE to solve them one by one, thereby expanding the range of data processing. "
Results using CADmeister
Realization of unmanned 5-axis machining
Dramatically reduced man-hours for NC data creation and on-site manned work
CAM-STRUCTURE is an automatic CAM system for structural part processing aiming at “automation of CAM work”, “digitalization of processing know-how”, and “improvement of unmanned processing rate”.
Automatically create machining areas from machining features (surface colors, machining attributes) and automatically determine the optimal machining procedures, tools, machining conditions, etc. for that machining area based on a knowledge database that has digitized machining know-how. Can be. In addition to creating a safe machining path that does not interfere with tools and attachments, it realizes safe unmanned machining such as rearranging the machining order according to optimization conditions, dividing processing according to tool life, and creating NC for dry run. .
CAM-STRUCTURE automation function
The ability to create machining paths for 5-axis machining using CAM-STRUCTURE has reduced the number of man-hours for NC data creators to create machining instructions and man-hours for on-site machine operators.
In preparation for preparation of NC data, DieStacker needed to merge objects into one, which required 400 hours of man-hours a year. You can work in time.
For mirror properties, DieStacker needed to create NC data for LH and RH using separate objects, but CAM-STRUCTURE allows work within the same object and uses mirror commands. As a result, the man-hours required for the mirror arrangement can be reduced. This has reduced man-hours by about 40%.
Expect CAM-STRUCTURE technical exchange meetings and UEL support for a system that can create NC data of easy and stable quality no matter who operates it
"Even though the data output rate is 90%, the actual unmanned machining rate is still only about 65%. On the other hand, if you apply them all at once, the processing machine will be over-controlled, so the processor will select the data to be processed while judging. In order to be able to do this, the data creation and machining staffs hold weekly meetings to work on improvements: First, achieve a data output rate = unmanned machining rate, and ultimately aim to achieve an unmanned machining rate of 100%. (Mr. Nishio) In
addition, Sankyo Co., Ltd. has full-time staff in each section of profile, shape section, and structure section, and creates NC data.
"I know roughly the work of each department as well as the staff of other departments, but it is difficult to substitute for the work, and by the time I can create the data alone It takes a very long period of time, so we want to be able to learn immediately regardless of who operates it, and to create NC data of stable quality smoothly even if the period is short. We are looking forward to CADmeister's Full Auto CAM being promoted. "(Mr. Nishio)
" I have an opportunity to exchange information with users who use CAM-STRUCTURE once a year, but more regularly It would be great if you could get together and get a new awareness or think about the features you want to add in a style like a study group. "(Mr. Ohashi)