CCAT recently completed a machining optimization project for Phoenix Manufacturing in Enfield, CT.  The part, a component for a next generation aircraft, is currently in low rate production at Phoenix but the demand for the part is expected to increase sevenfold in the coming years.
 
The current machining process has significant roughing cuts on a very capable OKK HMC at Phoenix.  Mark DiLorenzo, President of Phoenix, provided CCAT with his current NC code, the CAD file, the Ops sheet, & two pieces of stock.  CCAT’s modeling & simulation engineering team and the machining specialist analyzed the part using an optimization tool by Celeritive Technologies called VoluMill.  VoluMill’s optimization approach is to create tool paths that take constant volume of material cuts and dynamically adjust the feed rate.  This approach not only speeds up the material removal but increases tool life as well.  The recommended tool paths were then fed into Mastercam and additional improvements were made based on the experience of CCAT’s machining specialist.
 
Being the part is symmetric; a small sector of the total part was used to prove out the program.  Based on this trial run, it was estimated that a 50 % reduction in run time would be achieved.  Mark and his CNC programmer were invited to witness a run of this sample and discuss how the new machining approach would integrate with their finishing operations.  Pleased with the results thus far, Mark encouraged CCAT to run the full part.
 
As to not impact ongoing production at Phoenix, CCAT produced a 2nd fixture from a SolidWorks file Mark provided.  CCAT fabricated the fixture and the full part was run on the lab’s Hurco VMX42U.  By doing this, Phoenix was able to continue processing the parts as necessary in their facility in parallel to the process improvement work being done by CCAT.  Total run time for the roughing operation was reduced 70%.  CCAT provided Phoenix the optimized tool path for uploading back into their Seimens NX CAM package and their programmer was then able to append their existing finishing operations, and post process the file for execution on their machine.

“I gave CCAT a very complex part to optimize.  I knew there was opportunity for cycle time reduction, but didn’t expect a 70% improvement.  This is huge.” noted Mark DiLorenzo of Phoenix.

“We understand that many small manufacturers do not have the time to explore, evaluate, & learn emerging manufacturing technologies.   Our ability to work outside their production schedules gives CCAT the time to solve demanding machining issues that small manufactures may struggle to solve on their own.  This capability to apply the technology and actual produce demonstration parts makes CCAT unique.” noted Bob Torrani, Director of the Manufacturing & Supply Chain Initiative at CCAT.