Tag Archives: manufacturing

CAMWorks for Solid Edge Update

At this time there are a few things to announce. Apparently the API required for integrating assemblies has taken more work than they thought so the timeframe I was told for this to be done is probably January of next year. There is supposed to be an update that will have multi-axis and EDM later this month. There is now an SE user forum at the Geometric Camworks site so if you are a new CW4SE user go over there and help populate this. In general there are darned few user oriented things like tips and tricks at the Geometric site for users of both SE and SW flavors and the best source for help outside of tutorials still looks to be youtube, things like http://camworksguide.com/ and the Solid Professor stuff. Now let me say that the CAM differences between the SE and SW flavors is pretty small, (except of course we SE users have the killer CAD program;) ) and that what you learn from either side of the aisle where CAM is concerned will help.

I think sales have been pretty slow and I attribute this to the same problem SE has suffered under for some time. It is a puzzle to me why people expect the software to sell itself and not have to put their own money and time into an aggressive marketing campaign. A campaign that only has to talk about what this combination of CW and SE with best in class direct editing can do that makes it better than the rest to sell both SE and CW4SE. But I am not the smart guy PR wonk so I probably just don’t grok the genius behind the concept of no marketing is shrewd and effective marketing.

And last but not least in my world I finally have my seat of CW4SE and I expect to have some posts again soon on this topic.

I welcome anyone from Geometric who wishes to add or clarify anything. I have quit asking to be notified of any updates because these people do not respond until you chase them down. Evidently this gets back to the philosophy of PR management mentioned above.

ScreenHunter_04 Dec. 12 09.42

UPDATE 12-13-13
OK according to Ally PLM my dongle was supposed to be delivered yesterday. Now par for the course Geometric does not communicate. No notification or tracking number so no doubt it is still floating around where ever with whomever. Get a grip guys. When SE or ZW3d send me dongles or even version updates if delivered by DVD I get notification and a tracking number. Had you bothered to TELL me I would have arranged to be here yesterday.I have things to do today to and if I don’t get some idea of when to be here I will probably miss it again because I have to do things away from my shop. Is it so hard to act like a business that desires to keep it’s customers informed??

UPDATE 12-13-13 B
OK, 4:40 and the whole day is gone waiting for this to finally arrive and I had to cancel an appointment with a customer because of this. Now while talking to the UPS driver I see him scan the envelope and hand it to me. “No signature required I ask?” No this was not requested is the reply. “Do you mean to tell me that you would have just left this leaning up against the outside of the door like the other packages are when I am not here?” Yes is the reply. So let me get this right. A dongle that is worth $13,700.00 can be dropped off at my place with no signature and if this thing gets lost I suppose it would be my fault. Does anyone here see anything wrong with this picture?

OK, You Designed It, How Do You Propose I Make It?

One of my pet peeves is how the idea of designing things has become the end of the process of manufacturing for so many. I guess if I sat in a cubicle and all I knew was based on classroom training and I had never dipped a toe into a manufacturing facility I could think this way. Or if I was silly enough to think manufacturing began and ended with my scintillating but academic
design genius capabilities as I sat behind my monitor. So then this bit of enlightened design meanders it’s way through the process where hopefully someone with a bit of sense will see it before it gets out to the people who will be asked t0 make it.

Such were the thoughts going through my mind this week as I regarded a part that I had been sent to quote on. Now keep in mind these guys know what I have for equipment and they thought that this was a part suitable for milling.

ScreenHunter_01 Dec. 02 11.51

I am sure that all the plugin connections were dimensionally correct and that sufficient space in the “box” was allowed for components according to precise sizes garnered from somewhere. The problem is however that this designer had absolutely no idea of what is required to allow for milling this kind of part. First off this is impossible to mill unless done as four or five pieces that would be assembled with fasteners or perhaps welding. It could be done with some of those new fancy metal powder deposition laser doo-dads. Except for the problem of how to tap occluded holes in some of the round bosses I think it would be possible there. But then again this would never yield quick or cheap parts for something that was to be mass manufactured. You could afford to make one this way if it was to be used as a pattern for molding. But then you would have to drill and tap those holes on those bosses on every casting and quite frankly I don’t know a way that this would be possible except with a through hole which is not indicated based on the part file. In any case I am not familiar enough with casting to know if this is a feasible design.

What I am going to do is go through this part and show reasons why this cant be milled. It is my hope that perhaps this will get some of you who are not familiar with machining to reconsider how you go about designing. This guy spent his time designing something that cant be machined and at the very least he wasted his time and the time of shops sent RFQ’s.

Join me as we venture into the never never world of inexperience.

CAMWorks Handbook 2013

We all look for information that can be used to our benefit and of course I have been searching for info on CAMWorks for Solid Edge (CW4SE). There is not a whole lot of information out there yet and looking through YouTube videos and online searching does not reveal much. Geometric was supposed to be looking into a forum for CW4SE users but as of today no forum and darned few videos either. They are falling down on the job here sad to say. There is a lot of similarity between CW4SE and CW for Brand X though. It is my hope that Geometric would open up the CW4BX (Camworks for Brand X 😉 ) forum to CW4SE users though. I understand that they may not want us posting over there but the CAM problems that those guys run into will be the ones we will also run into I would think. I have asked that they open it up for us to be read only but no reply to that idea as of today.

As an aside here and speaking of forums and the Siemens BBS. I wonder if any of the mucky mucks in PR and Marketing have noticed that the guys that don’t wear suits, that be you SE users by the way, also have the largest number of posts BY FAR in SE Misc over any other category. Perhaps the SE guys should be dictating what goes on there since clearly the SE users are the most active. Perhaps the lack of starch and suit jackets in our haberdashery and attitudes just might be a good thing for the whole BBS and Community sites to embrace if they want lots of readers. Just a thought and this thought not approved by PLM World, Darth Vader nor the masters of the straitjacketed public face of Siemens. In addition here is a link that is up to 52,000+ views as of today that ought to be making these straitjacket guys rethink their isolation from the real world. I wonder just how prolific the sales of SE really would be if the corporate marketing and PR roadblocks to success were removed?

In the mean time let me get back on track here and ask you where do you go when it is after hours and you want a question answered? The best solution I have found is the “CAMWorks Handbook 2013” by Michael Buchli and here is the web link http://shop.camworksguide.com/

This PDF also comes with 80 minutes of video and of course when you are banging your head on the desk at 10:00PM or on the weekend and wondering how to do your part tech support is not available. Not that any of us ever find ourselves working past 3:30 in the afternoon and never on weekends of course. $49.95 gets help on your way and I have bought it and I consider it the best single resource I have found yet for CW4SE. You SolidWorks Camworks users should also look into this and for the price how can you lose?

Solid Edge for Manufacturing, Old Insulator Stack

Here is an obsolete Westinghouse part that still is in service with electric utilities that needs to be replaced. As is typical with many of these obsolete parts there is no blueprint or file provided so I have to have a physical sample to measure from. This one had a lot of small variances as you can imagine both from manufacturing tolerances which were generous and spark erosion on the inside from use. I use a Gold Faroarm to reverse engineer things like this. In general you can tell what the intent was with the old parts and keeping in mind that simple numbers like fractions were used in many cases on old parts you can interpolate from your collected data and arrive at an accurate and useful part.
Westinghouse Insulator Stack

In this case there were ten different parts in the stack and I will be able to use one jig to cut nine of them.
Westinghouse exploded

Once you have the parts created what is the problem to be solved for machining these is how to hold them for cutting. In past versions of SE it has been a multi-step rigamarole thing to get this done. In ST6 much to my delight this is no longer true. Now it is a simple thing to create an assembly and drag a part into place on a block and create a perfect workholding device for cutting. What I will be showing is the setup for one type of part and how to hold it in place while machining. Being able to do this for a family of parts quickly and easily is key to how much money you are going to make on short run items. I will have twelve sets of these to cut and more than likely will not have any again for a year. Please note that I will not be machining the jig block itself for the sake of time here. It is what happens elsewhere that is interesting. So follow me as I demonstrate how the combination of ST6 and Camworks makes more money with less hassle in my shop.

Later this month by the way CW4SE will have assemblies capabilities in it if you care to use it. With this method that I am going to demonstrate however you pull your xyz zero off of the corner of the block for the cut plan and when you clamp your part in you are good to go. Subsequent parts in this family of parts can be brought into the assembly and positioned with their common hole center patterns and each of them can be saved out as separate parts just like the first one was and cut plans derived for them using the common xyz zero. It is not necessary to have a separate assembly file you have to bring in for every single variation here. In reality it is not necessary to have an assembly file at all in your CAM plans to still be able to benefit from assemblies. Obviously the holes in the rectangular blank stock are the first step in a separate operation with a different clamp method working off of stock xyz zero. Two vice-grips and a strip of metal on another 6″ x 6″ plate will do for blasting the holes out.

Folks, bear with me on the occasional hiccup here. It is time out of a workday to do this and you would not believe how many times you have to go through these things before they are perfect. Try making a video yourself and see. I spent enough time on this one to get close and that is good enough. And yes I know after reviewing the video that I moved the block .09 and not .10 for the zero point but you understand the intent here and can duplicate the correct result on your own parts with the directions here.

Join me as I create the jig and part and then cut with SE ST6 and CW4SE

CAMWorks 4 Solid Edge Comments and Thoughts

In a bit of a holding pattern for now until September for posts on actual CW4SE parts I will be working on. However there is a bit of news and a bit of reflection and comments upon CW4SE.

As of right now there is no forum for CW4SE. The official Geometric forum has a section for SW users only and this should be changing soon and will include a section for SE users. Even though the basic program is the same it has been Geometrics decision that SE users should not have access to the SW users forum. Since both are closed forums I guess that you must have a seat of one or the other to access them. I have no idea what will be there and it is a shame that years of experience as cam users on the SW side of things will be roped off to SE users but with the politics that could result I guess I can understand why the two will be kept separate.

I don’t think SE at the official BBS site has any intention of having a forum either and the one time I mentioned a need for one it was met with a rather curt reply from a Siemens guy that this was Geometrics job and not Siemens. Sometimes I wonder about who talks to who and who plans these things as I would have thought that a forum would have been planned and who was responsible for what would have been picked and resources dedicated. Support for CW4SE is important and unless the VAR’s are slated to fill this area I am not sure how smooth the initial support for CW4SE will be. I think this gets back to the Dart Board idea I promulgated some time back where planning is chaotic and meetings are had to decide what to talk about in the next meeting and then another one to determine if the first two meetings were effective and on and on they go. People, time passes and this is a roll-out of a new product and an important addition to SE’s ecosphere. It is important to get this right and we are months after SEU2013 and this forum is still not established. But beyond the forums there is another category and it is who does your potential VAR have as a trained support guy? CW4SE is a new integration with SE but it is not a new program. I am hoping all the major VAR’s intend to have a veteran of CAMWorks for SW on staff to answer questions on the CAM side. The program is the program and if your VAR is intending to provide support based on freshly trained guys who have not themselves cut chips with this program it could be a problem. Make sure you ask your VAR of choice what he intends to do in this area. I have no idea what Siemens official policy is towards mandatory minimum support required of VAR’s to sell CW4SE and so it is left up to the buyer to be aware of this. Make sure your VAR can support you before you buy would be my suggestion.

There is a book out there, “The CAMWorks Handbook 2013” that is for the SW integration that looks interesting. Obviously the CAD side of it is for “Brand X” and includes nothing for direct editing 😉 but from what I have read and seen with the CW4SE manual given out with the program (I assume it will be the same one I was given during beta testing) it may be a decent alternative learning method for the bits and pieces of CAM needed to decide what features are needed to do differing CAM plans. Disregard the constant references to the class B modeler and you should be alright. If I order the book I will report on what I find.

There have been webinars from various VAR’s out there. I don’t know what all of them are doing but I do know that Saratech has a veteran CW user running theirs. Now is the time by the way to tell your VAR’s that you expect at least one guy in the organization that has actually cut chips with CW4SE to be there for support for CW4SE. Remember that the only time you have to get your wishes across to these guys is going in so push for all you can before signing with one.

On the program front as planned and announced some time ago September is rapidly approaching and working with assemblies will be an additional function to be released then. I don’t know what else is coming out and as I have reminded people if they want it talked about they have to release information. Hopefully this will happen soon.

In any case I expect to have my seat soon and then it will be on to some real parts. One thing I will be interested in is how CW4SE will work for a small shop like mine where automation and the Tech Data Base setup is not so beneficial. I want to just recognize features I want to pick and go from there and also avoid populating the TDB with my own tools so I can just pick them as I go. For instance, the TDB has a lot of tools in it but not one three flute endmill. This is the preferred endmill for cutting aluminum and as it is recommended by Volumill for just this I am surprised that Geometric did not have any of these in the tools for milling section. The TDB is an area where there could be improvements made and from what I gather in talking to some SW users of CAMWorks they agree. Now the TDB is a powerful tool for automation and I think is particularly beneficial for larger shops with a system set up for tool and machine management but this is a little complicated for those who just want to pick a tool, or input the cutter data individually for each tool path and go from there. In My old program for instance I can scroll through a list of tools and just pick it and edit it right there if I need to and save the new tool to the library. Far easier than this TDB thing is. Of course I am quite familiar with the old program and not CW4SE yet so my opinions here could change as get used to using it. It would be nice if Geometric would allow for the importing of tool libraries into their TDB from manufacturers but as of right now you have a tedious excel like chart to fiddle with and you have to add these things in one by one. It would also be nice to be able to do away with having a tool library required to create a cam plan and just pick and assign tools to the cam plan and have it be remembered as tool whatever in spot whatever and then just save it. Automation is really cool for those shops that want or need it but some greater consideration for those shops that don’t want this would be nice.

One of the things I really liked during beta testing was the constant step-over tool path. I was over at the HSMWorks forum the other day and they were complaining about how tough it is to get a constant scallop heighth there. Kind of like I use to have to do with ZW3D you have to create different tool path stepovers at differing places in the part to get a really consistent finish on the part. So you end up with four or more toolpaths to do almost as good as the single toolpath in CW4SE will get you quickly and easily. Just a word here by the way. I find some of the CW4SE GUI to be clunky and some of the nomenclature to be worded in such a fashion that it is hard to remember what it means. So welcome to the real world where no program is perfect and they all expect you to learn according to the idiosyncracies of each different set of programmers. Many of which I believe don’t really grasp what actual users want because they have never cut chips and don’t understand our work flows and the reason for how we choose our work flows. The programmer liked it and it made sense to him so it must be right, right? But don’t mistake my grumbling about these things to be really serious objections to the program as a whole. I know enough about it to state that the improvements to my bottom line for cutting efficiencies will be large over time compared to programs I have used in the past. And of course the fact we now have true integration between CAD and CAM.

The insanity of allowing programmers who have not cut chips to be the final determiners of how a program is set up to work for users is a topic for another day and I am of the opinion far greater heed to user wishes should be made. I am afraid that with Geometric, like most other software authoring companies, once the program gets out the door the silliness is programmed in and it will take an act of God to get programmers to understand that just because what they did can be made to work does not make it the right way or the best way to work and to then fix it. Kind of like how dumb is it that SE still after all these years does not yield accurate manufacturing data for threads but someone in Programville decided it was OK so every user subsequently has to struggle with this. I bet this comes back to haunt them as how can they recognize accurate manufacturing data on holes imported from say SW if they can’t do it for their own program? You use software to design or cut I am sure you have pet peeves based on programmers choices too and this problem is everywhere.

The Parable of “O’Charleys” Restaurants and Solid Edge

O’Charleys is a restaurant chain based out of Nashville TN that I used to do a lot of work for. In years gone by they had franchise holders and one of them owned a store on University Drive in Huntsville not far from SE’s headquarters. And it is this store where this story began.

My wife had been a server at O’C’s for a while and I had worked on probably over a hundred of their stores by then. We were very familiar with the standards that were supposed  to be in place for service and hygiene. At that time they had the best Prime Rib you could buy and so we decided to go to this store for a meal.

Well we get in there and sit and wait. For quite a long time actually before the waitress could be bothered to approach us. In the mean time I go to the restroom and come back out with a bit of disgust as I tell my wife what a foul smelly cheap bar place it was. Still no yeast rolls and these were supposed to be quickly presented according to corporate policy. None was ready it seems and so the waitress could not bring them out until after we had our salads. Big no-no and the server attitude was lackadaisical at best as she was more interested in talking to friends than customers.

I came back to the Commissary operations for O’Charleys which was in Nashville and my biggest customer at that time and told some of the people there how awful the meal was. Their comments to me were “did you tell Wayne (franchise holder who also had an office there) about this? I was a little hesitant to do so but they prevailed upon me and I did so. Talked to Wayne about it and described from beginning to end what I saw and experienced there. Wayne did not have much of a response and I left his office.

A few weeks later I ran across him and asked him about the store and this is what he said. He went down there and walked in unannounced for a surprise little visit and it was every bit as bad as I said it was. He spent some days there getting things fixed up again and firing the managers that had allowed this to happen. I asked him how this situation had occured when the store was just a two-hour drive away from the offices in Nashville and easily checked on.

Wayne went on to tell me that the numbers from the store were decent and based solely upon this there was no reason for him to go there. He had six other stores  so I guess he would concentrate on the worst one only. I don’t remember asking him about this so I can only conjecture.

Some time  later I asked Wayne about that stores numbers  and he said that after his surprise visit and  ensuing cleanup and management purge there was a pronounced uptick in sales.

The moral to this story is that numbers only do not tell the complete story. Here we have Solid Edge whose numbers are decent and sales are going up in spite of how the help is presenting the “food”. They should be and could be much better is my belief.

It is not just the basic quality of the food you sell but it’s appearance and presentation too. You can have great food and spend lots of time sending out select aged prime rib from the commissary but if the people “selling” it in the store don’t do their job it will never matter how good the commissary’s beef is.

Does A Solid Edge Publicity Department Really Exist?

I have been thinking about this at great length and I conclude that in spite of what I was told about publicity and my commitment not to talk about it for a while I have to now comment. The reason for the original decision is I think still valid but there is another problem that is systemic with UGS/SE and now Siemens and it is a different one.  It is a publicity department that does not have a clue about the passing of time and what to do. 3D has asked me questions for instance about the rent SE by the month announced at SEU2013. And here we are a week after and just nothing.

Lets look at this particular problem. I believe this was one of the major vehicles being offered to entice potential full-time new customers. So here we are heading into SEU2013 and we know it exists. Karsten talks about it and speaks of it in the keynote address. So you publicity wonks, I now have a few questions for you. Why was there not a cohesive plan to promote this with details worked out and on the shelf ready to go on day one in Cincy? Why do I have to sit here two weeks later and tell people I don’t know because you either don’t know or can’t make a decision to tell the public about it? I thought the days of Bruce Boes advertising paralysis were over but by golly I find myself wanting to look behind closed doors to see if he is still here. Do you people understand that you only have one major event/product release a year and you have to utilize it to benefit from it? The buzz never burst upon the scene in my opinion because it is the same old same old long time employee total lack of vision and do it the way we have always done it because my head might hurt if I do something radical. And apparently profuse timely publicity and the free flow of information is a radical concept to these publicity people.

Here is another one. There is to be some sort of ST only version of SE that  I believe was created for two reasons at around $2,000.00 I think if I remember this right. My belief is that it was meant to be a competitor to things like SpaceClaim as a direct editing reduced function program for CAM users to use and also as a cheap way of getting the power of ST into more hands. I don’t hear anything about this and I thought this was a big deal. Evidently the PR department thought it was not as they can’t be bothered to talk much about it or provide many details about it that I have seen.

Where are the ready to go videos showing the power of ST in assemblies this year? Why were these not done well in advance of SEU2013 and posted on YouTube on 6-25-13? Now that I think about it why were there not videos on every important aspect of ST6 posted on YouTube no later than the first day of SEU2013? You knew what you had to work with six months ahead of time and I just have this vision of people standing in a room with a dart board in front of them. It has various PR categories around the bullseye and after the darts are thrown the arguments ensue and the whole process starts over again and again. I can just see it. A dart misses the board and now we have to debate if this means there was a category that should have been on there but wasn’t and nothing is ever decided or done.

I was forbidden to talk about some of the things I knew about CAMWorks because, well because someone somewhere decided that the perfect and anointed time to do so had not arrived. A totally farcical situation considering the fact that this whole integration and the company it was to be done with had been publicly announced A YEAR AGO! Do you people understand that if you talk about it and have a vendor there showing it in SEU2012 it is not secret to be hidden knowledge? Alright let me see if I can put it in terms you all might understand. When PT Barnum comes to town they make a big deal out of it and they have (shocking I know, the very thought scares me) a PARADE to entice the public to be their customers. So as I remember, you PR guys can help out here if you wish, the only mention for the next ten months about this came from a blogger that does not reach all that many people. But for months I did more to promote CAMWorks for SE than Siemens did and I just don’t get this disconnect. Is there something wrong here or am I just an idiot for thinking that if you want people to buy your product your better promote the bejeebers out of it?

Which leads me to my next topic. Where the heck is all the info, the Powerpoints and videos from SEU2013? Do you ever intend to release these? You do know the time to have done so was 6-25-13 don’t you? It should have been canned and upped on the site of choice and ready to go with links active the night before SEU started. You do want to create buzz don’t you? You do want to compel people to consider SE don’t you? Then here is a suggestion from Remedial Marketing 101. I say remedial for a reason because evidently some individuals have to be taught first that marketing has value before they are taught how to do it. Tell you what. I don’t have to sit in a room and argue with people or worry about perfect timing or whatever you guys do that stops worthwhile plans and efforts dead in its tracks. I was given a flash drive as were HUNDREDS of other attendees and it has the SEU2013 Powerpoints on it. (You know, the ones you have not released yet. But they are public and this is what bothers me so much. WHY oh WHY is this stuff not out there yet that I can find) I am going to help you guys get off the dime and give you a week to stop prevaricating. Then I will figure out how to post the whole thing to my blog.  Who do I send the bill to by the way for doing your job for you?

Heaven help me and I know JB will have a field day with this but the day Jon Banquer makes more advertising sense than what I am seeing from the PR wonks at Siemens or SE or whoever it is responsible for this mess I just cringe. Can you imagine that even he is getting this right but none of the paid advertising people are? I have to admit that I find defending inaction is not a task I am up to and so I am not going to. I guess the idea of “The Best Software You’ve Never Heard Of” has legitimacy as advertising genius to “The Best Publicity Department We Never Hear From”.

I think hands down SE in its combination with CAMWorks is the single most powerful mid range MCAD program for manufacturing out there. I believe in it enough to spend my own time promoting it and I don’t get compensated to do so. As a matter of fact it costs me some money and time out of my life I can’t replace because I do believe in it. It makes me furious to watch this neglect from those who are paid to promote SE not do so and not do so for year after year. I can’t conceive that once again we are heading down the path of anonymity and the opportunity provided for PR with SEU2013 is being squandered for reasons I don’t know and can’t begin to fathom.

Why don’t you people get off of your dead rear ends and start earning your money? I am at the point where I don’t care if people in the PR department are offended because I darned sure am offended. What do you people do with your time? What can you possibly be thinking to let this precious time go by? Dassault and Autodesk are doing everything they can to destroy their businesses and all the plans that Karsten and his team come up with for the future are just shot down by your incompetence. This is your last year to get it right. I don’t believe this hiatus of coherent planning at Autodesk or Dassault will last more than another year. When they get whipsawed by declining on-maintenance and new customers they will reconsider their ways and your free ride will be OVER. These guys know what they are doing in PR and they will eat your lunch.

The question is do you even care?

Update 7-9-13

Had a Faroarm rep here today at the shop. While talking I of course mention SE. I mention SE because he was talking about Faroarms being integrated through Dezignworks to work with Solid Works, ProE and Inventor. We continue talking and he is familiar with SpaceClaim because some of the machine shops that have Faroarms are using it with the new Spark program. He has heard of SE just a few times over the last five years.  WAY TO GO MARKETING AND PR!! I know very well there are a number of SE users in Tennessee which is this guys district but he does not and this is the result of a total failure to effectively communicate the SE message here.  I hate it when people look at me like I am delusional when I say this software they have rarely or never heard of is better than SW. I just wish I could send these people straight to the publicity/marketing departments of SE so they could see what dismal failures they have been at getting the word out.

The primary reason he had not dealt with SE is because nothing has been set up with Faro to work natively inside of SE. And of course the lack of any publicity for SE reaching him through the internet or other media.

Solid Edge for Manufacturing, CAMWorks for Solid Edge Constant Stepover

One of the family of parts I design and manufacture is extrusion dies for Polin Depositors. One of the recent designs is one you have seen in other posts as the Guitar Die. Soon if you go to the Music City Arena in Nashville  you may just find a guitar crouton next to your salad or maybe a chocolate chip cookie made with this die for the Polin Depositor.guitar die top

Now this part has presented problems before with finishing where the corner round goes into the cavity. The way I have had to deal with this to prevent stair stepping in the past has been to basically create three or four cut paths to accommodate varying degrees of slope.

Besides the Volumill routine in CAMWorks for Solid Edge (CWFSE) my second favorite tool path is constant step over. This gives me a constant step over based upon the distance across a face and not just in “Z” or “X-Y” as was my previous fate in life. Now a word of warning here. This tool path follows contours it assigns across your part for maintaining this constant step over. This can result in gouging if you are using this path to cut down to a face. The way to avoid this is to create a contain or avoid feature and this will stop the tool path from gouging the floor of the part.

Guitar Die closeup

Is this not a beautiful thing? It did not matter where I looked in these cavities all the tool marks were completely concentric. I used a sketch  profile around the cavities for containing and picked tool on the profile and I have a perfect blend going into the hole and then completely down to the bottom. Now keep in mind the finish can be as fine as you want it to be if you are willing to spend the cutting time to get there. This quality of finish is good for this type of application and requires nothing finer.

I can see that many of my 3D parts will require two tool paths only. Volumill with intermediary step cuts at sufficiently small cut amounts to allow for going directly into the constant step over finish tool paths.

CAMWorks for Solid Edge Beta Team

Beta Team

Wanted to take a bit of time to thank the BETA testing team for CAMWorks for Solid Edge. Some of these guys flew in and spent four days of time in Huntsville and we all spent time there and afterwards fiddling with stuff new to us. So from left to right we have Solid Edge users and testers Tim Hoeing, Dave Ault, Joe Hourihan and Larry King. Jim Wright from Siemens, Marc Bissell from Geometric and Mark Burhop from Siemens.  This was a small team because what we were really testing was the interface between Solid Edge and CWFSE. The CAM program is robust and proven but the integration with SE was new. I have been particularly impressed with how quickly and dramatically this integration has improved from the first beta version we had to this last one from 6-19. I look forward to using again a completely integrated CAD and CAM program and not having to look for another CAM program again in my working career.

A special tip of the hat to those with Siemens who knew that things the way they have been were not good enough and they determined to change this to the way things should be.  This lack of CAM integration was perhaps the single largest remaining vestige of the Venture Capital types who are so good at buying up companies and then saddling them with new debt, starving them of funds, direction and R&D while writing themselves grossly out of line benefits packages.  It appalls me to think of both the damage to the companies and then to this head below the radar cookie cutter mentality that has become so pervasive here they are having to work on as a result of these guys. Who knows where Solid Edge could have been if someone like Siemens who understands what CAD and CAM and PLM etal software really is about had bought them before the loot and plunder venture guys did.  I am sure that the competitors of UGS/Solid Edge have really enjoyed watching them being shackled but those days are over.

Just as a reflection upon the CAD and CAM community with any software here. It takes people who are willing to spend some of their time they can’t replace to help things move forward to the benefit of all concerned. From a local user group you participate in or help to run up to beta testing software so what is released can be better your involvement is important. Have you considered getting involved in your software of choice to make it better?

Solid Edge for Manufacturing, Thermal Dynamics of Cutting

One of the things I considered when shopping for a new mill was High Speed machining. The idea that smaller end mills at higher RPM’s would yield more cubic inches of metal removal per hour than old school big hog slow rpm ones would. And that in addition my mill would be hammered a lot less and the end mills last longer. Another consideration keeping this in mind was the choice between a direct in line spindle or a gearbox driven spindle. I chose the direct drive 10,000 RPM one for my mill for two reasons. A better finish possible due to vibration reduction from the gearbox and the fact that the in line spindle actually has a much higher torque output than the gearbox does from around 1500 RPM if I remember right on up to the max RPM.  The only serious consideration I had for the gear box was tapping holes but then thread milling is the answer for tapping problems above 5/8″ which the in line drive does just fine.

So I am cutting some tool paths for the first time with Volumill and I thought why not get some pictures of this. Just like freezing Humming Birds in flight with the camera lets just see what chips look like was my thought. Volumill chips

Now I had been told that the best way to cut steels and stainless steels  was with carbide and to cut it dry with proper feeds and speeds. This produces nearly complete heat transfer from the cutter and work piece to the chips. Part of the problem with coolant and carbide and HSM is that carbide does not withstand the thermal shock of heating and cooling that happens with being engaged in the cut and then quenched with coolant. It will break the edges down prematurely.

So I get the trusty old camera out and the above picture is the result. I thought it was interesting how hot the chips were that they would have temper colors just six or so inches away from the cut. Now let me tell you these chips were moving fast and there was a lot of heat there. When we finished the roughing cut on this part I put my hand on it and it had barely perceptible heat above what the table on the mill had.

This part we were cutting was 4142 steel and we were using the Milling Advisor recommended f&s of 10000 RPM and 269 IPM. I for one find it quite fascinating how technology advances in all areas at the same time to give different results where the rubber hits the road. From the carbide substrates and coatings in the end mill to the algorithms used in Volumill and the idea of faster smaller deeper cuts with in line spindles we get a whole new way of productivity. And seeing is believing.