The communication of construction and production is usual nowadays. Is it the same for the further application of construction data for the CNC machining? Though there is a high potential for quality improvement (incorrect data entries are excluded) and cost savings (time to market), it is very rare today. How can a metalworker increase his value added?

Elusoft, a subsidiary of elumatec group, optimizes the connection of profile bar machining centres to CAD systems through automatical data generation and visualization.

elusoft, a subsidiary of the elumatec group, optimizes the connection of profile bar machining centres to CAD systems through automatic data generation and visualization.

CAD data for the production?

CAD systems of metalworkers serve in a lot of companies mainly for the expense budgeting. The ordering is often integrated, as you need parts lists for the calculation; offers have to be gathered from the provider. For a simple saw control you can take the existing data of profile length and cutting angles. Unfortunately they are insufficient for the control of machining centres: beside the geometric data (header: "where do we need which machinings?") the technological data is nearly always missing (e.g. tools, tool parameters like feed rate, clamp positions etc.). All these designations should be generated by the CAD program for different types of profile machining centres. 

With other words: a pure CAD system is completely overstrained. The existing data has to be edited. elusoft works pragmatically. In the first step the interfaces between construction and production will be checked (see box), then the demanded adaptation of the data will follow.

Machining macros are insufficient

Most of the CAD systems generate macros for the machinings, to be executed at a special position at the profile. The actual machining and the complete technological data for the machining are in the machining centre. Such a macro is a simple description, colloquially: "A bar at 220mm from the bottom at the profile and a further bar at 220mm from the top." An experienced machine operator can program its machining centre, but this is strenuous and full of errors.

To automate this step (at least partially), you can create a sub-program on the machining centre, containing machining steps, the machine can really convert. In this sub-program you can find the machine-specific data and the parameters of CAD system, e.g. profile type and measures, macros and macro positions. So you get the real detailed machining program.

The advantage is obvious: all repeating machinings are deposit once and and can then be used. The disadvantages are also clear: the number of macros can get quickly too large and you have to create and deposit new machine-specific macros for each profile type and machining sequence. If a client works material-related, generates a profile system, all machining models have to be determined, all macros defined and created - in the CAD system as well as in the factory.

EluCad closes the gap

Elusoft has the solution: EluCad. The program builds a bridge between these worlds, in adopting, editing data from CAD system and assigning it to the machine. The software with modules for entry, 3D presentation (with OpenGL) and outputs with postprocessors for different profile saws and machining centres administers all profile and machining data centrally and at a place which enables to adapt a machining program automatically to different machines. If e.g. a 8mm hole is needed, but the suitable is not available on the machining centre, EluCad generates automatically a machining cycle for the machining with a 5mm milling cutter. In case of efficiency or breakdown of a machining centre, the order has simply to be diverted to another one, without changing the program.

Short machining and optimization times

The operation is adjusted to the Windows Explorer. The machinings will be defined at the profile in a machining tree, where the different levels can simply be fade in or blanked. Clearly arranged entry masks and realtime 3D presentation of generated data guarantee an efficient and safe programmation. CAD data can be adopted in format Wicona or NC-X. After having generated the machining data for the machining centre a machining sequence will be optimized. Beside the parameters the traverse path and the tool change times will be considered. The result is a reduced machining time of the machining centre.

Result:

Consistent interfaces between CNC machines and CAD systems did not exist yet in metal-structure for the integrated profile machining. The specialists from elusoft, well acquainted with both "worlds", closed this gap with EluCad. The automated data logistic reduces the errors drastically, accelerates the conversion from construction to production and increases the flexibility at processing of orders.