Four Methods to Streamline Part Programming

Automation and other means of streamlining the programming process are an efficient way for job shops to improve cycle times and job profitability, judging from several CAD/CAM stories I’ve worked on recently. Feature-based programming, canned cycles, associativity and toolpath simulation all promise shorter, more efficient programming and machining — and case studies suggest they can live up to that hype. Let’s examine each a little further:

Digital twins and associativity have improved Willis Custom Yachts’ ability to address revisions to parts and implement lights-out manufacturing. Image courtesy of Siemens.

Feature-Based Programming

Feature-based programming focuses on common part features (small holes, pockets, grooves and the like). Several modern CAM systems can detect these and drop in readymade (or nearly) tool paths that handle these parts. This can significantly cut the effort required to program a part, with Open Mind’s Uday Honnalagere saying it can save 70-80% of programming time. This still leaves the most complex areas of part programming, which programmers can tackle fresh instead of after inputting in standard, repetitive features.

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Some CAM software also enables users to add their own automation features or refer to proven part programs to gain some of these benefits with more complex parts. These features grow more helpful to users as they build them out, and are especially for part families.

Canned Cycles

Similarly, many CAD/CAM providers have added canned cycles that enable programmers to automatically handle complex operations that might make for more efficient tool paths, even as programming without aid could prove difficult. Tom Funke at Sandvik Coromant spoke to me last year about some of these, including trochoidal turning, five-axis dynamic milling and ramping down, which he says can improve tool life even as they shorten cycle times.

Some providers pride themselves on canned cycles for specific kinds of tool paths or cutting tools. These specialties can take advantage of the specific features of a cutting tool, such as Open Mind’s Hypermill does when adjusting the contact point of a barrel cutter’s radius.

Associativity

Even tiny differences in models between CAD and CAM can lead to tolerance stack up or other errors, an issue multiple providers have attempted to solve through associative CAD/CAM suites that directly translate models between CAD and CAM software. Direct connectivity between these programs also simplifies communication between design and production departments, in many cases giving shopfloor teams access to updated designs without manual file transfers. This form of revision control can also inform both design and production teams when a design change conflicts with the geometry expected at a particular point in the machining process, enabling them to solve the issue before errors occur.

Tool Path Simulation

Increased support for digital twins and toolpath simulation also helps CAD/CAM users preempt errors. Joseph Alonso, founder of Novo Modo Machining, says the simulation within Hypermill has enabled his shop to change first-part runs from 10-20% rapid in single-block mode to 40-60% rapid at full feed rate, reducing production time by 33%. Bobby Cody, Willis Custom Yachts’ director of manufacturing, says simulation with digital twins within Siemens NX has enabled the shop to run its custom parts lights-out while cutting over 95% of scrap, ultimately doubling machine utilization and lowering part delivery times by half.