KPI Machining, Sheridan Illinois in order to stay productive and profitable in their CNC machining while providing quality parts, took to CAD/CAM technology to give them an edge.
KPI Machining is a job shop that produces CNC milled and CNC turned components with an importance on producing low quantity orders (1-500 parts).
When KPI turned to technology to help them succeed they found BobCAD-CAM for CNC programming software. KPI now uses the BobCAD-CAM Mill Pro and Lathe CAD/CAM to design and produce parts ,fixtures and their tooling.
KPI Machining reported that they rely on BobCAD-CAM for accurate 3D milling for solid modeling and programming of complex geometry for their CNC lathe. Obtaining a cycle time from a machining simulation allows them to more accurately quote parts. they also use BobCAD-CAM to produce technical sketches for customer verification and procurement of outsourced services.
The CAM software gave them all of the high speed elements they needed without having to spend much. Cutting tools included a 1/2-inch XPVS500-030 carbide end mill fromSupermill. The part was machined at 2250 RPM, 56 IPM on the initial test run with an 8% climb step-over, 8% conventional step-over and 1 inch engagement. The Initial run came in at 3.3 lbs removed in 6.8 minutes and the same roughing tool was used to machine over 55 parts!
The same tool was being used for roughing the next operation. But KPI preferred to use the 1/2-Inch cutting tool since this component required that size or less for finishing as well as that the tool cost $65 and it can be sharpened again by the manufacturer, then the BobCAD toolpath can quickly be re-programmed to use the re-sharpened cutter. Hencesaving them more money. They prefer not to implement a variety of different type roughing tools on such a low quantity run as this is equivalent to less money in the job, less setup/programming and operator intervention.
KPI reported that the Adaptive Roughing function is surprisingly easy to program and takes no longer than a drilling operation to setup. No chirping in corners equals maximum tool life for carbide, and no unforeseen gouges in the part from tool deflection in corners.
Very consistent finishing stock is left all around the part even without an additional profile pass to clean up. Negligible spindle load or axis load is easy on the machinery and this is inevitably easy on the companies maintenance costs.
KPI Machining can depend on BobCAD-CAM Mill Pro and Lathe software to get parts out the door by taking full advantage of the software’s ability; 2D drawing, 3D modeling, and providing a variety of toolpath options that give an edge in the their market.
The toolpath capability BobCAD-CAM provides allows KPI to manufacture complicated parts, fixtures and tooling easily and efficiently. It seems part families and component design changes are no more an issue for KPI due to the software’s structure.
If something changes on a part, they simply re-sektch, select and compute them again, the toolpath due to the ability to associate the part model to the CAM Tree. Another huge advantage is getting the choice to name and then save individual machining features for later use. The 3D simulation is extremely remarkable in the fact that it shows an actual tool holder geometry, tool protrusion and length of cut of the tool. One can observe problem areas in his program before the code ever gets posted.
In words of Eric Pine, Production Manager in KPI Machining in Sheridan Illinois BobCAD-CAM is the foundation of their working.
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