CAD/CAM for grinding on your machine tools

CAD/CAM for grinding on your machine tools

12 Jul 2023 | CAD/CAM

More precise than traditional machining operations, grinding enables the surface of a product to be finely modified thanks to the abrasive machining technique. Nevertheless, investing in the right machine tools to perform this type of operation represents a significant cost for companies, more so as their piloting can prove difficult for programmers. To facilitate grinding on these machine tools, some manufacturers are exploring the possibilities offered by CAD/CAM. But what additional advantages does CAD/CAM offer this activity? Here’s how.

The challenges of rectification

By employing the principle of abrasive machining, grinding achieves exceptionally high dimensional accuracy on parts, enabling us to meet customer requirements better. Whereas traditional machining operations involve the removal of a swarf, grinding acts more finely on the material, polishing it with a grinding wheel.

While the effectiveness of this method is not in doubt, it nevertheless represents a significant investment for companies: they must purchase the machine tools required for these operations. The challenge for organizations is to measure the profitability of the proposed solutions. To carry out grinding operations, they can:

  • Either invest in grinding machines dedicated exclusively to honing.
  • Or to invest in combined machines for both machining and grinding.

The limits of “foot-in-the-machine” programming

In the first case, i.e., with a solution that combines machining and grinding, companies can adapt and create grinding programs for the machine.

The disadvantages of this approach are manifold:

  • Lack of flexibility: unlike CAM, this programming does not allow machine simulation and collision checks.
  • High cost: this type of programming requires the purchase of a grinding machine in addition to the machine tool, plus handling costs.
  • Risk of inaccuracy: Moving parts from the machine tool to the grinding machine amplifies the risk of inaccuracy.
  • Considerable programming time: programming machine tools and setting up grinding machines can be time-consuming for the teams in charge.

The range of CAD, CAM, ERP and PDM TopSolid solutions

CAD/CAM to optimize grinding on machine tools

Faced with these limitations, some manufacturers have developed combined machines which, thanks to CAD/CAM, allow:

  • First, machine a part by milling and turning.
  • Grind the same part in a second step.

The part does not need to be moved, as all handling is done on the same machine. This eliminates repositioning errors caused by moving the part from the machining center to the grinding machine and saves valuable handling time.

Point of attention: the need for a dedicated grinding CAD/CAM tool

For companies equipped with machines that combine machining and grinding, choosing the right CAD/CAM software is crucial. Only some CAD/CAM solutions contain dedicated grinding operations; some propose diverting machining operations into grinding operations. This is not a very relevant approach, as the method used to pilot a grinding wheel differs significantly from that used in milling or turning.

This type of solution offers no added value to the programmer, who is forced to manually adjust the ISO code to obtain the correct surface finish on the part. This is why companies are strongly advised to opt for a CAD/CAM tool that has specifically designed the grinding operation.

 

TopSolid’Cam: a software designed to optimize grinding on machine tools

TopSolid’Cam is a complete, high-performance CAD/CAM software package that supports and facilitates the design work of programmers thanks to:

  • Easy and complete solution integration.
  • Interoperability with all CAD software.
  • A self-managed working environment.
  • Production optimization thanks to a duplication process.
  • Different simulation levels.
  • Change management and tracking.
  • An answer to a wide range of milling and machining needs.

More specifically, TopSolid’Cam’s “grinding on machining center” functionality enables customers equipped with machine tools to combine machining and grinding to optimize the management of this operation. Indeed, the solution offers the possibility of programming the grinding process directly from the software, even before the part is mounted on the machine. Designed explicitly for on-machine grinding, this functionality adapts to the characteristics of each operation and facilitates the programmer’s work.

Would you like to learn more about TopSolid’s machining center grinding functionality? Ask our team for a demonstration.

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Success Story: TopSolid by Rabumeca

Success Story: TopSolid by Rabumeca

20 Mar 2023 | CAD/CAM

Based in the Ain region of France, Rabumeca designs and manufactures welded assemblies in steel, stainless steel, and aluminum for various sectors. Founded in 1989, the company boasts many years of experience in its field, which earned it the “quality, cost, delivery” award from ArcelorMittal in 2013. Since 2020, Rabumeca has been integrating TopSolid’Design software into its design process—interview with Sébastien Bridet, Rabumeca’s Managing Director.

Experience, know-how, and commitment: the recipe for a successful company

Backed by over twenty years of experience, Rabumeca has gradually expanded into the food, pharmaceutical, steel, and environmental sectors. Today, it employs 20 people and expects sales of 2.7 million euros in 2021. At the heart of the company’s project is the determination to offer quality services within set deadlines and the desire to establish a relationship of trust with its customers and business partners.

Rabumeca’s deployment in various industrial sectors has enabled the company’s employees to develop a wide range of technical skills. Over the years, the company managed by Sébastien Bridet has also expanded its expertise through a policy of investment aimed at improving equipment reliability and performance. The collaboration with TOPSOLID came naturally.

Rabumeca and TOPSOLID: A Recent History

In need of new CAD software to boost productivity, Rabumeca launched a call for tenders in 2020. For the company, the choice of TOPSOLID was obvious: “We chose TopSolid because they were the only ones who understood us and listened to our needs. The people we spoke to were experts in their field, and they knew how to adapt their design software to our manufacturing process“, says Sébastien Bridet.

In application, employees use TopSolid’Design to launch manufacturing and design products for special machines. Nicolas Laibe, project manager at Rabumeca, describes the process in detail: “I use TopSolid’Design to retrieve 3D files from customers and provide the technical information required for the project. I use the sheet metal and tube recognition modules to obtain the documents required for manufacturing. In this way, the software enables him to construct “everything from laser flattening to bending sheets, assembly drawings for sub-assemblies, and assembly drawings with all the corresponding bills of materials.”

TopSolid’Design supports Rabumeca’s development.

Specialized CAD/CAM software, TopSolid’Design efficiently supports Rabumeca’s projects. An accurate productivity tool, the teams particularly appreciate its ease of use.

Support throughout the entire process

In TOPSOLID, Rabumeca found a pedagogical partner who was able to guide the company’s employees through the software: “We had a 6-day TopSolid’Design training course at TOPSOLID headquarters, and we had a specific training course on our premises, adapted to our needs“, explains Sébastien Bridget. In his opinion, the quality of the support staff made the difference: “We found people who were able to respond to our needs and questions daily and who were able to support us throughout the implementation of the software.

Ease of use

For project managers, TopSolid’Design represents an added value to design, mainly ease of use. Nicolas Laibe explains: “I find TopSolid’Design very easy to use; it helps us have the right documents. It’s logical and clear, with the right icons and functions. It’s very similar to what we use in the workshop.

Productivity gains

More generally, TopSolid’Design has given the company a real boost in productivity. With over a year’s hindsight, Rabumeca’s managing director comments: “TopSolid has enabled us to automate all the tasks we used to do manually. The working documents saved us enormous time when we launched our processes. According to him, the productivity gains achieved by the company thanks to the software are far from negligible: “We estimate that we have gained around 30% in productivity in the methods department“, he asserts.

The range of CAD, CAM, ERP and PDM TopSolid solutions

Development prospects are closely linked to TOPSOLID.

Rabumeca’s objective for the near future is to develop its functionalities to meet its customers’ needs even more effectively. Sébastien Bridget wishes to integrate TopSolid’s quotation module into his organization. By setting up facilitating systems, this module makes obtaining a result close to workshop reality possible via a 2D or 3D part drawing. Proud of their achievements, TOPSOLID will again be delighted to support them in this process!

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Mechanical engineering: making a successful digital transition today to better meet tomorrow’s productivity objectives [WHITE PAPER]

Mechanical engineering: making a successful digital transition today to better meet tomorrow’s productivity objectives [WHITE PAPER]

6 Jul 2022 | CAD/CAM, ERP, PDM

Industry 4.0, through the digital transition and the adoption of new technologies, is the main challenge for mechanical industries. Robotization, implementation of management systems, simulation, digital twins, production management, workshop management, Cloud computing… In the coming decade, all companies in the sector will have to implement one or more of these technologies. However, for these technologies to be truly effective, they must communicate.

Computer-aided design and manufacturing (CAD/CAM) software, enterprise resource planning (ERP) software, manufacturing execution system (MES), product lifecycle management (PLM) software, workshop management systems, etc. Once equipped, the challenge for companies will be to make all these systems interoperable to ensure digital continuity, from design to production.

How is the digital transition changing the world of industry? What are the requirements for a communicating CAD/CAM and management software? What are the advantages of an integrated digital solution for the mechanical industry?

This white paper aims to help you adopt the right strategy for integrating CAD/CAM, ERP, MES, PLM tools, etc., to make your company’s digital transition successful. 

Follow the guide!

Making tool management simple – Is it possible?

Making tool management simple – Is it possible?

7 Apr 2022 | CAD, CAD/CAM, CAM, CAD

If producing machined parts for your manufacturing tools is a complex process, should the system that is supposed to make it more efficient be a “necessary evil”? Considering the cost of stopping production because a part is missing from the tool magazine, the necessity of a good tool management system seems obvious, but it does not have to be complicated as it should be designed to make your processes more efficient and safer. Here is how.

1) “Tool Management”: what do we mean by that?

Tool management encompasses physical tool management in a workshop as well as all the technical data attached to each tool and component used in your manufacturing process. This is usually handled by a dedicated software designed to assist machine parts manufacturing by automatically loading technical data into the CAD/CAM system as well as managing tools’ and components’ physical inventory.

Tool management becomes even more important when considering next-generation CAD/CAM software. Based on 3D modeling, machine kinematics, advanced simulation and many other tools needed to create high-precision machined parts, a lot of data is generated to ensure that the products coming off your assembly lines are of the highest quality.

This data needs to be accurate, up-to-date, available, and ready to be retrieved. This way, you avoid inaccuracies and save time and money in the overall process, which also means improving profits.

2) Challenges that come with tool management

Since tools and components for manufacturing processes are a very large and complex topic, one of the biggest challenges is the interface to get the 3D data into the CAD/CAM application. Indeed, in addition to the 3D graphic, a tool also contains many parameters and functions in space that form the basis of the toolpath algorithm in CAM. If there is a single faulty parameter, the operation in CAM is invalid and cannot be generated.

Another challenge is that most of the available solutions on the market only work by pure database application, which means that you only get a graphic view (and not a 3D visualization) of the part to be produced. This makes it confusing and complicated to use, especially for occasional users. Most of these solutions do not facilitate 3D data management or even offer a functional interface for CAM applications.

3) The benefits of a good tool management solution

If all the data for each tool and component are centrally managed, any information can be retrieved at any time and from anywhere in the company. In addition, good tool management ensures that all references and back references are stored, not only for transmission to the CAM system, but also for all existing NC programs. This allows you to better plan for new programs as well as improve change management.

A good tool management solution also provides you with a real time picture of your tool magazine on the shop floor, allowing you to directly synchronize your machine magazine with your CAM environment. Therefore, by centralizing production data, you can optimize your workshop organization and increase overall productivity by:

·       Reducing machine set-up lead time

·       Improving traceability of program modifications

·       Providing precise tool location

·       Monitoring the use and wear of tools

4) Advice for beginners

If you are thinking about implementing a tool management system, you should look for a solution that will help you to efficiently manage your tool components, your assembled tools, their life cycle, and is running on a single data source that is always easily and readily accessible. But above all, it should be adapted to your activity!

The tool management solution you consider should be able to adapt to your existing processes, workflows, and growth strategy by being completely modular and scalable. Think big in order to be able to implement additional modules in the future!

You should also be able to build on your existing NC data. As you are not starting from scratch, your tool management solution should automatically take into account your existing data in an intelligent way. Indeed, you cannot afford to stop production while you fill in and set up the database. The system must be able to connect existing data, learn and expand while using it, and integrate it step by step.

5) Why TopSolid’ShopFloor can answer your needs in terms of tool management

What makes TopSolid really unique on the market is that there is no interface between the tool management system and the CAM application. TopSolid’ShopFloor is a product that is completely based on TopSolid’PDM as are all TopSolid solutions. Thus, components and tools are controlled by revision, oriented towards properties and BOMs like a “standard” part or assembly and are fully associable with all modules available in TopSolid (CAM, Design, Draft, …).

To easily create components and assemblies, TopSolid provides libraries to create your own components from fully parameterized ISO 13399 models. Of course, you can also import and use supplier data. TopSolid’ShopFloor supports all data, even data from other tool management systems.

Searching for components and creating assemblies are simple and can be managed via TopSolid’ShopFloor Tool Manager. The fully graphical drag and drop assembly process is very user friendly and is a great help in daily activities.

In other words, a system that:

  • has no interface
  • does not translate or transform any data to create the toolpath
  • builds the data source on the TopSolid core

We can 100% guarantee that a tool defined in the TopSolid environment is functional throughout the process, from CAM to presetting and machining.

TOPSOLID is a leading CAD/CAM software company in the world. With more than 35 years of experience, we are able to offer fully integrated CAD/CAM solutions adapted to your industry, whether it is in mechanics (machines, tools, etc.), sheet metal or wood industry. Wherever a machine interacts with the material to be machined, whether to shape or produce a part, we have an adapted, innovative, and unique solution. To learn more, contact us!

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Industry 4.0: Challenges and perspectives for the factory of the future and intelligent machining

Industry 4.0: Challenges and perspectives for the factory of the future and intelligent machining

19 Jan 2022 | CAD/CAM, ERP, Machining

In a context of fierce competition where globalization is omnipresent and consumer habits are changing, companies have no choice but to change their manufacturing methods.

The factory of the future will have to be agile and connected in order to ensure its competitiveness and productivity. It will have to handle the diversification and changing needs, producing in shorter time frames, while being environmentally conscious thanks to its energy efficiency. We have been talking about Industry 4.0 for several years. What are the challenges for companies? What does the “factory of the future” mean?

​

What is Industry 4.0?

 

Concept and origin of Industry 4.0

A concept first highlighted at the Industrial Technology Fair in Hanover, Germany, in 2011, Industry 4.0 is a reference to the first three industrial revolutions.

The first industrial revolution took place in the 18th century after the invention of steam engines, allowing mechanized production. The arrival of the electricity grid led to the rise of the second industrial revolution at the end of the 18th century. Finally, the automation of production in the 20th century led to the third revolution.

The idea behind Industry 4.0 is to reverse the trend of globalization to the advantage of European industries by encouraging factories to acquire the latest technological tools, all connected via the Internet and the Cloud.

In the new factory, the idea is to put the factory at the service of the operator, not the operator at the service of the factory. Since people are the central factor in this plan, every effort is made to improve the ergonomics, productivity and safety of each workstation. As the evolution of production methods has led the operator to carry out more and more procedures, the objective of the ultra-connected factory is to dematerialize all these phases, so that people are focused on tasks with high added value. To do this, each machine will be connected and communicate with the network, and the information will be transversal to be distributed between the different departments. Information will be disseminated smoothly and efficiently from the customer’s purchase order, through all stages of the manufacturing process, to the shipment of the finished product.

 

Industry 4.0 components: What are they?

The connected factory, or factory of the future, is not going to revolutionize everything. It will use existing equipment, improve it, and then place it at the heart of a network where all the information can be shared.

For this purpose, certain tools are essential to support the change:

  • The Internet of Things will allow the development of newly manufactured products, therefore opening up new market opportunities.
  • 3D printing opens up new production possibilities, able to adapt to the competitive production of small series.
  • Collaborative robots (Cobots): as operator assistance, the cobot will improve the productivity, safety and efficiency of some workstations.
  • Augmented reality: By juxtaposing information related to certain procedures (notably maintenance) to the individual’s visual field, augmented reality will allow you to rapidly intervene by following the displayed procedures.
  • Cyber-physical systems (CPS): They allow new features to be added to physical elements for the purpose of process control and management. It becomes a key element in the information chain.
  • Industrial big data: The gigantic database of the factory of tomorrow will evolve into “Smart data” with the introduction of artificial intelligence. It will notably improve predictive maintenance.

The range of CAD, CAM, ERP and PDM TopSolid solutions

Challenges and perspectives for the factory of the future

 The challenge of the 4.0 factory will be to increase productivity while adapting to a new way of consuming. Today’s consumer is buying more and more and tends to focus on customizing objects. So one of the main challenges of the factory of the future will be to combine productivity with mass customization and reduced series.

To do this, it will be necessary to facilitate the use of programming software to save time, so that the individual can use them very quickly. One of the objectives will be to process the information in a very short time, while maintaining flexibility in the parameters.

The machining of the future will require the implementation of an intelligent system, capable of self-assessment and correction. The goal of Industry 4.0 is to create “intelligent machining”: the collection of know-how and process data, combined with artificial intelligence, for the benefit of production.

 

How does TopSolid fit into Industry 4.0?

Although the concept of “Industry 4.0” appeared only a few years ago, TopSolid did not wait for the fourth industrial revolution to follow this logic of the factory of the future.

TopSolid has been offering a fully integrated digital chain for years via its suite of CAD/CAM software suite, therefore providing total interconnectivity from design to construction.

 

TopSolid continues its evolution towards the CAD/CAM of the future, which involves:

  • Intelligent design: in addition to 3D models already well recovered at the geometric level, the recovery of machining information (PMI) and tolerances, as well as taking into account milling and turning operations.
  • More automation: predictive calculations: vibration calculations, deformation of parts due to clamping; refined tool life management (with calculated cutting conditions); families of similar parts (adapting to customized mass production); automatic range generation.
  • Using the cloud: collecting the company’s BigData, deporting greedy calculations, constantly updating the software.
  • Putting people at the heart of the 4th industrial revolution: change management, setting up certified training courses for the mutual benefit of companies and their employees.

 

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Say goodbye to the boundaries between the Design Engineers and the Process Engineers, thanks to TopSolid!

Say goodbye to the boundaries between the Design Engineers and the Process Engineers, thanks to TopSolid!

17 Jan 2022 | CAD/CAM

It’s a fact: jobs, missions, methods, organization, tools and work habits, … everything seems to oppose the Design Engineers and the Process Engineers, and this happens within many companies. The two entities often do not operate in the same environment and are geographically distant. The lack of interaction between the two departments can sometimes create what we speak of: a “border.”

However, at the time of Industry 4.0, where connectivity and communication in all directions are a strategic necessity.  The divide between the IT department through the manufacturing department tends to become a structural issue for the company’s performance.

Let’s discover how the TopSolid digital solution can break down these walls!

1) Design Office VS Process Office: two entities often in opposition within a company

 

A) Reminder of the missions of each

Design Office

Between engineering and expertise, the mission of the design office revolves around advice, recommendation, and control: 

  • As a subcontractor, the design office receives and evaluates the feasibility of its entrusted external projects.
  • As an integrated department within a manufacturer, the design engineer is responsible for designing projects for their company’s customers.
  • Project management also falls within the scope of the design office, which must ensure compliance and traceability.
  • Finally, the design office draws up a detailed plan of the design and sends it to the process office.

An innovative mission dedicated to service

 

Process Office

As the linchpin between the production line and the design office, the process office is responsible for implementing the project from the design office. Its mission has several facets:

Validation of the product’s feasibility after studying elements such as modeling, average dimensions, the geometry of the raw material, or machining assembly. 

– Industrialization: it is the study of the means (tools, machines, operators, materials, and equipment) and the solutions to be implemented in the manufacturing process.

– Optimization of work organization (flow management, access, handling, etc.) and machining (time and cost management) to increase productivity.

They monitor machinery and equipment: reporting the need for maintenance or replacement.

– Management of the conformity of the production about the operating procedures (order of operations, tools used, number of people, and time required to carry out each task).

A multi-faceted mission at the heart of which is naturally a strategic need for communication with the design office.

However, often these exchanges between departments are far from being fluid and collaborative.

 

B) Two worlds that can clash

Creative on one side, functional on the other, and incompatibility of opinions … the reality is hardly subtle. Moreover, the lack of geographical proximity can also factor in.

It so happens that the mission of the Design Office lies in the conception of innovative projects resulting from R&D and consequently presenting a very elaborate technical plan. As such, the department can misrepresent these gratifying aspects, with other departments or subcontractors, thus obscuring how the projects will be industrialized… or even the project feasibility! 

However, the Process Office is in charge of industrializing the projects issued by the Design Office … an endemic situation inevitably puts the two departments in opposition, with the Design Office defending innovation and considering the Process Office as the “brakes” on design and creativity … the Process Office, for its part, is not always able to respond favorably to the conceptual project because of a proven lack of solution.

Should we accept this state of affairs as inevitable and “deal with it”?

2) The disadvantages of a two strong opposition between Design Office and Process Office

 

One thing is sure; the two departments speak the same language: that of 3D modeling, average dimensions, raw materials, machine set-up, and tolerances. There is no shortage of opportunities to exchange information for the smooth running of the project: information needed for industrialization from the design office to the manufacturing office, as well as requests for clarification or revisions before launching the machining, from the manufacturing office back to the design office.

But when the border between the two departments is unbridgeable, a cascade of dysfunctions harmful to the entire organization ensues:

  • Waste of time in post-design discussions; each defending their own position.
  • Increased risk of errors and data loss if there is no direct exchange interface.
  • What about the automatic recovery of part properties and manufacturing characteristics for process office or design office patches?
  • And then … we talk about the work atmosphere and motivation?

It is mainly from this cumbersome operation that tensions arise. The loss of time due to a lack of reliability and traceability is the number one enemy of efficiency. A situation that increases standard costs potentially decreases the quality and puts a heavy burden on productivity… not to mention the delay in deadlines!

In short, the exact opposite of what is expected to meet the company’s strategic challenges. How, then, to create the bridge between the design office and the process office to close this counter-productive border?

 

3) TopSolid: the solution that links the two worlds

 

Going from a product idea to its industrialization implies, in the current context linked to Industry 4.0, the practice – and if possible, the mastery – of several so-called “basic” requirements:

  • a shared thinking process on the global project scale
  • a single, reliable, shared information, to frame and manage exchanges
  • fluid and factual communication
  • a reactive decision-making process
  • a genuine and synergistic collaboration

Also, to connect and rally the two departments falls under a logic of synergy of the processes, the objective being to achieve the rigorous management of the geometrical data, the orchestration of the flows, and the collaboration. An ambitious challenge that TOPSOLID takes up with brilliance!

TopSolid’s CAD and CAM solutions are developed on a common database (PDM) with an intuitive user interface and are associative. In addition, the design process integrates all the tools in line with the manufacturing process: the updates of the parts follow in CAM, and the process office can even make slight modifications in agreement with the design office.

With this highly successful CAD/CAM software solution, TopSolid meets the needs of today’s companies:

  • Data control: the PDM of the solution manages both the technical data of the design office and the manufacturing office, thus allowing the full recovery of the “parts and manufacturing” characteristics.
  • Traceability: TopSolid automatically transfers CAD modifications to CAM, managing common modification indicators.
  • Streamline and secure the exchange of information: with TopSolid, file conversions, data entry, and risks linked to errors and data loss are over.
  • Efficiency: By merging the design and manufacturing processes, the collaboration between the design and manufacturing departments is improved, thus boosting efficiency and motivation.
  • Increased productivity and improved quality.

Suppose this new configuration of the relations between the design office and manufacturing office requires to know how to manage the change (company culture, working methods, tools, …). In that case, it also constitutes the beginnings of digital continuity, so essential to the industrial requirements of tomorrow.

As you understand, fluid and collaborative communication between the design office and the manufacturing office allows the border between the two departments to be erased… And because data volumes are increasing and work flows need to be justified, it has become difficult for industries to pass up a software solution. TopSolid, through its CAM, CAD, PDM, and ERP applications, enables the simplification of exchanges between the design office and the manufacturing office, ensuring the coherence of projects, and secures the design and manufacturing processes while reducing their cost. The time saved is colossal, and the efficiency of the design and manufacturing teams increases. In the end, it is the company’s productivity that improves… A successful challenge!