Aerospace supplier needs fast CAM solution that can program anything: Aerospace Dynamics International uses NX CAM to speed NC programming for large, complex parts produced on high-speed, five-axis machines

Aerospace Dynamics International

Aerospace Dynamics International no longer has time to code intricate machine motion by hand, yet it still needs the control that hand-programming provides.

Difficult jobs, tight deadlines

Aerospace Dynamics International (ADI) manufactures large components such as aircraft wing spars and bulkheads and panels for the space shuttle’s external fuel tanks. Due to their large size and critical applications, these parts can be difficult to machine. “Our parts are very large and we must hold extremely close tolerances,” explains Brian Carlson, NC programming manager at ADI. “Yet our customers are raising the bar higher and higher each year in terms of how soon they expect delivery.”

In the past, ADI’s programmers used either an Automatically Programmed Tool (APT)-like NC programming language to code toolpath motion by hand or an earlier-generation graphical CAM program. There were drawbacks to both methods. With hand coding, it was possible to achieve very precise toolpath motion even on high-speed, five-axis machines. But hand programming took a long time. Another drawback was that it was difficult for programmers to work on each other’s projects. “They had to be dragged kicking and screaming to another’s job. Coding style differences had become a big problem,” says Carlson. The other method, using graphical CAM software, sped NC program creation somewhat but it was still labor-intensive when used to create toolpaths for high-speed machines. It was also difficult to revise five-axis programs once they were generated.

Complete programming control, easy to make changes

The installation of seven seats of NX CAM gave ADI the combination – fast programming and complete motion control – needed to meet customers’ tight delivery schedules. NX CAM’s developer, Siemens PLM Software, pioneered high-speed machining (HSM) technology, working in conjunction with machine tool and controller manufacturers. For jobs that require HSM on five-axis machines, NX CAM has become ADI’s software of choice.

“With the sequential mill function in NX CAM, we can get the tool to do anything we want, even for something complex like five-axis finishing,” says Carlson. “The software can program any feed rate change, any step-over, looping passes, whatever we need.” NX CAM also makes it easy to modify existing NC programs. “If the machining technique doesn’t work, it can be a real bear in other CAM systems to modify the code,” Carlson adds. “With NX CAM, it’s much easier to make changes.” Carlson says that thanks to the efficiencies of NX CAM, ADI programmers using this software are putting out a very high volume of work.

Productivity boost, hours saved

Having CAM software that can create complex toolpaths accurately saves ADI a great deal of time. A good example is the NC programming for ribs of a commercial airplane. The work was originally done with the APT-like language and took 400 and 260 hours, respectively. (The higher number is for the first in a series of programs; the lower number is for the last in the series, which draws upon the work of the earlier programs.)

When the company won the contract for similar airplane ribs, Carlson decided to have the programming done in NX CAM. “The first program took 260 hours, the second took 190 and the third took 152,” he says. “On the first program with NX CAM, we equaled the best we could do with all of our experience in hand programming. On the last, we took more than 100 hours off the best time we had ever accomplished by hand.”

Programming for space shuttle fuel panels used to take 10 days per panel with hand coding. With NX CAM, one panel (the last in a series of six) was recently programmed in only three days. “That was very fast but all six were perfect to plan,” Carlson says. “The motion was every bit as good as hand-written code.”

Download the PDF:

Aerospace Dynamics International

Challenges:

• Deliver large, complex components to aerospace OEMs on increasingly tight schedule
• Find fast yet highly accurate method for programming highspeed, five-axis machines

Keys To Success:

• Import customers’ Catia files
• Use NX® CAM’s sequential mill for complete control of five-axis NC programs
• Take advantage of software’s planar mill and sequential mill tools for fast roughing

Results:

• Greater volume of work produced per NC programmer
• Toolpath creation for airplane wing ribs down from 260 to 152 hours
• Space shuttle fuel tank panel NC programming dropped from 10 days to three

Industry:

• Aerospace & Defense

Client's Primary Business:

Aerospace Dynamics International Inc. is a $60 million-a-year prime vendor supporting the aeronautics and aerospace sectors.

Visit Website

Business Initiatives:

• Production Efficiency

Solutions/Services:

• NX
• NX CAM

Client Location:

Valencia, California
United States

"People say that you have to use a programming language such as APT to get total control over machine function. But we have total control with NX CAM, and it's much faster than hand coding."

Brian Carlson

NC Programming Manager

Aerospace Dynamics International