WorkNC-MPM makes big savings at Formenbau Blank

Sescoi’s new module WorkNC-MPM (Multi-Part Machining) is proving a hit at Formenbau Blank GmbH. The company has been using WorkNC since 2000, brought about by the need for 3D CAD/CAM. Anton Traub, Master Toolmaker and CAD/CAM Manager at Formenbau Blank, justified this step, “We were very satisfied with our existing CAD/ CAM system for 2.5D geometry, but not for 3D. Using WorkNC is remarkably uncomplicated, and its ability to recognise residual material makes the software the ideal addition for us”.

<< Previously, I had to allow around three hours for setting up and checking a pallet, today it takes a maximum of 20 minutes >>
Anton Traub, Formenbau Blank GmbH.

The mould manufacturing company produces 80 percent of the tools used by the precision casting company, Feingu Blank GmbH, whose workforce of around 300 produce seven million precision castings annually, using approximately 2,400 tonnes of steel and iron. Formenbau Blank provide tools for lost wax casting of steel and non-ferrous alloys, and understands the need to utilise high technology equipment both in machine tools and in CAD/ CAM, to maintain its position as a premier toolmaker.

Formenbau Blank’s experience with WorkNC is that every machine operator can create his own CNC programmes. Anton Traub said, “Anyone with a thorough knowledge of milling will have no problems in quickly creating functional and operational NC programs with WorkNC. He simply selects the tool, a few more parameters are automatically extracted, the desired strategy is determined, and at the push of a button WorkNC generates the finished machine programme. In addition, Sescoi makes a proven postprocessor available for each current machine tool.”

Manufacturing complex electrodes is a key part of the mouldmaking process, Formenbau Blank needed to mill pallets of different electrodes together in one set-up. Sescoi understood this and developed WorkNC-MPM, which Formenbau Blank has been using since the beginning of 2003. The software allows many parts with different geometry to be clamped together in one set-up, so it is ideal for machining of multiple electrodes on one pallet. Each individual part is programmed in WorkNC, but not postprocessed. Once grouped together the tools used on each part or electrode are optimised, so that each cutter is used across all the parts before a tool change is initiated. Additionally, by considering the complete pallet as one job, the software eliminates the possibility of a collision.

Anton Traub gives a practical example, “We have standardised pallets with space for up to 20 electrodes. For each one we need between six and ten different tools.

This means that if we work through them one at a time, we are facing as many as 200 programmes and tool changes. Optimised machining using WorkNC-MPM, which considers the entire pallet as one component to be machined, and therefore uses each tool only once is of great importance to us.” A high number of tool changes would have a large impact in terms of time, costs and accuracy. When four minute warming up phases to get the tool to operating temperature, are associated with tool changing – necessary for precision high speed machining, the benefits of WorkNC-MPM are clear.

Postprocessing the optimised toolpaths takes place right at the last minute. This produces further advantages for the company as machining with the first tool can start immediately. While it is cutting the first toolpath, the programmes for the remaining tools can be created so that the operator loses very little time. “Previously, I had to allow around three hours for setting up and checking a pallet, today it takes a maximum of 20 minutes”, said a delighted Anton Traub. The last minute postprocessing also provides flexibility. Choosing which machine tool to use for manufacture, and reaction to project or component modifications, can be achieved with one mouse click, automatically regenerating the new cutter paths. The reliability and safety of WorkNC-MPM are further decisive benefits. Anton Traub said, “The man at the machine previously had to enter all the zero points manually and link the programmes together. WorkNC-MPM now does this automatically and thus excludes any source of error.”

In the time that WorkNC-MPM has been in use at Formenbau Blank the engineers have been convinced of it capabilities. With this software, processing pallets loaded with different components is markedly faster and safer than processing the individual objects one after another.