SERMO, ARRK's specialist in large size moulds, deploys WorkNC.

SERMO, a key part of the ARRK Corporation, has been using the WorkNC CAM/CAD system ever since Sescoi launched it in the late 80’s.

<< The reliability of WorkNC’s 5-axis module has contributed greatly to our success. >>
Julien Golly, CAM Manager, Sermo France

Sermo, since its formation over 40 years ago, has grown into one of world’s largest toolmakers with an annual turnover of Euros 50 million and a workforce of 600 at eight sites around the world. The skills and resources it has, combined with those of its parent company ARRK, give it the capability to manage highly complex projects in the automotive plastics components industry.

As ARRK’s representative for France, Germany and the UK, Sermo France manufactures large moulds for components such as bumpers and instrument panels, adjusts moulds produced by other overseas members of the Corporation, and carries out the 5- axis machining of aerospace parts.

Julien Golly, Sermo’s CAM Manager explained why the company chose WorkNC to programme its machines, “It provides us with an automatic and highly reliable solution, which has significantly reduced leadtimes and raised quality levels.” Sermo examined several solutions for collision avoidance before opting for WorkNC, which today allows it to fully exploit the capabilities of its latest high speed and 5-axis machine tools. Julien Golly added, “The performance and speed of deployment, together with the way in which collision avoidance operates within the programming environment, enables us to carry out toolpath modifications very easily and quickly. We have been able to reduce machining times by 40% for finishing operations thanks to WorkNC’s collision avoidance.”

Continual development of the software by Sescoi has produced many new toolpaths, while demands from Sermo’s customers have led it to cut new and tougher materials which are difficult to machine and require special techniques to produce a satisfactory result. Version 18 of WorkNC included new Adaptive Trochoidal Roughing paths which automatically introduce a spiral shaped trochoidal movement whenever full engagement of the tool is detected. For hard materials it allows the speed of machining to be greatly increased, as heavy and shock tool loads are automatically avoided. Furthermore, by defaulting to climb milling whenever possible cutting conditions are optimised. Julien Golly said, “For these tough materials we were experiencing excessive tool consumption, with tools frequently lasting only five or six minutes. With the introduction of Adaptive Trochoidal Roughing, tool life has increased by a factor of ten.”

Sermo has now introduced the toolpath for standard materials where it is achieving tool life improvements of between 10 and 15%. Included with the latest version of WorkNC is Dynamic Stock Management. This important new function automatically updates the model of the excess material remaining after each operation in real time. For the company, having accurate information about the location of stock material as machining progresses helps to avoid air cutting and enhances the performance of WorkNC’s collision avoidance. Julien Golly added, “By considering the interaction between the machine, the tool and the toolholder, as the part is cut, we get absolute reliability.”

The expansion by Sermo into the 5- axis machining of aerospace components has been enabled by WorkNC’s continuous 5-axis machining paths, and has enabled the company to become an important supplier of complex aerospace parts. Julien Golly commented, “Sescoi gave us valuable advice and assistance in implementing 5-axis machining, helping us to evaluate the most effective way of using the WorkNC 5-axis module. Its reliability has contributed greatly to our success.” 5-axis machining is now an established part of Sermo’s working methods, allowing it to achieve significant productivity gains on jobs which were previously machined entirely in 3-axis or 3+2 axis.