Automotive And Transportation JK Machining
Automotive and transportationJK MachiningAutomation helps a machine shop thrive in acompetitive marketplaceProductNXBusiness challengesMaintaining competitiveadvantage over globalcompetitionDelivering high-quality moldsfaster so that customers canget to market fasterAbility to accommodatefrequent design changesReducing production costsKeys to successUse integrated NX CAD/CAMsoftware to develop andmachine moldsNX enables JK Machining toincrease efficiency with a digitalthread throughout the entiremold design and manufacturingprocessClass 101 mold expertsFounded in 1980 and located in Kalamazoo,Michigan, JK Machining specializes in thedesign and manufacturing of plastic injection molds. The company primarily servesthe automotive and medical device industries. JK Machining’s automotive customersare Tier 1 and 2 suppliers producing mostlyinterior components – air conditioning outlets, trim bezels, cup holders, and otherinterior components.JK Machining focuses on class 101 molds extremely high-production molds with fastcycle times, made from the highest-qualitymaterials and designed for one million ormore cycles. The industries served by thecompany share some of the same trends:their demands for higher quality require better mold parting lines, better finishes andtighter tolerances. The underlying issues forboth automotive and medical customers arequality, delivery time and cost.Shrinking delivery times, improvedquality and lower costs“We used to have 18 to 22 weeks to build atool for automotive,” says Henry Kalkman,president of JK Machining. “Now that’s downto 10 to 12 weeks. All of our customers wantLeverage mold-specificdevelopment toolsUse of high-speed machiningmethodsAutomate design, NCprogramming and machiningwith NXSave and re-use bestmachining methodsUse of 5-axis machining toimprove quality and reducemachining timewww.siemens.com/nx
ResultsSeamless mold makingprocess – from design tofinished moldsReduced average molddevelopment time from20 weeks to 11 weeksAutomated the entire moldmanufacturing processReduced programmingtime from hours to minutesEfficient design changemanagementReduced machining time byup to four times using 5-axiscapabilitiesto get to market faster. Offshore moldmakers have an advantage in cost, and arebringing up their level of quality – they areour main competitors.”JK Machining meets these challenges headon with state-of-the-art technology and ateam of 15 dedicated employees with deepexpertise in mold design and manufacturing. The company operates a manufacturingshop with advanced-capability machinetools including high-speed machining centers, grinders, mills, and electrical dischargemachines (EDMs).Gaining an advantage withleading-edge technologySeveral years ago, JK Machining sought toupgrade its computer-aided design andmanufacturing (CAD/CAM) capabilities toimprove efficiency and competitiveness. Thecompany selected NX software fromSiemens PLM Software, which includes leading-edge CAD and CAM capabilities and specialized mold design tools.Formerly, JK Machining had used separatesoftware systems for mold design and manufacturing. To move from design to productionrequired the company to export data from thedesign system in a neutral exchange format,then import the data into the CAM system fornumerical control programming. This transferand translation of data introduced additionalsteps and errors in the process that hamperedproductivity. Furthermore, the data translationand transfer steps complicated the handlingof inevitable design changes, which are difficult to track and implement correctly throughthe convoluted process.“ Automation and continuous improvements usingNX helped us build a reputation for deliveringhighest quality molds on time. That’s how westay competitive and grow our business.”Henry KalkmanPresidentJK Machining.
JK Machining’s previous NC programmingsoftware solutions lacked key capabilitiesthat limited the types of jobs the companycould undertake. When JK Machiningacquired high-speed, 5-axis machines, theNC programming software proved to be difficult to operate and to customize to betteraddress its specific requirements for speedand efficiency.JK Machining selected NX based on severalkey characteristics of the software. With itsfully integrated capabilities, NX offeredautomation of the entire mold developmentprocess, from design through manufacturing. The CAD tools of NX include powerfulfunctions for working with geometric models provided by customers, as well as moldspecific capabilities that support an efficientbest-practice workflow for mold design. ForNC programming, NX CAM software delivered leading-edge tools for 5-axis and highspeed machine programming that wouldenable the company to take full advantageof its advanced machine tools. With thisintegrated system, JK Machining establisheda digital thread that enabled processautomation throughout design andmanufacturing.Support from Siemens partnerCAM Logic, Inc.JK Machining relies on CAM Logic, Inc., aSiemens PLM Software solution partner, forsupport and implementation consulting.“The support we get from CAM Logic, Inc. isespecially important when we get newversions of the software,” says HenryKalkman, president of JK Machining.“They help us understand the newcapabilities of each release and how wecan best apply them.”Developing molds with NX“We used to have 18 to 22weeks to build a tool forThe typical mold design process atautomotive. Now that’sJK Machining begins when customersdown to 10 to 12 weeks. Allsend CAD models of the parts they want toof our customers want to getcreate and a request for a quote on the projto market faster.”ect. The CAD models are usually in theSTEP neutral interchange format, andHenry KalkmanJK Machining imports the geometric dataPresidentinto NX. To prepare the quote, JK relies on itsJK Machiningextensive experience in mold design.“I know intuitively what a mold base or a hotrunner will cost from past knowledge,” says“The mold analysis tools areKalkman. “Our expertise allows us to quicklygreat – I can easily identifyprepare accurate bids, which is critical in ourundercuts or places wherebusiness.”we need more draft. I canlook for thin or thick walls,Mold design begins immediately whenand automatically determineJK Machining is awarded a project. The comthe total weight of the moldpany makes extensive use of the specializedand its center of gravity.”mold design tools of NX Mold Wizard to create the mold base and design cores and cavi- BrianMold Designerties, runners, cooling lines and other moldJK Machiningfeatures. “Using NX is light years beyondhow I used to design molds in 2D,” says
Brian, a mold designer with 30 years ofexperience who has used NX for more than10 years. “The mold analysis tools aregreat – I can easily identify undercuts orplaces where we need more draft. I can lookfor thin or thick walls, and automaticallydetermine the total weight of the mold andits center of gravity.”Brian is enthusiastic about the other automated NX mold design capabilities. “Themold design libraries are real time savers,and we have added to them over the years,”he says. “NX Mold Wizard has simplified andautomated design changes – when we get arevised part model we can just drop it in,add shrink, compare the old part to the newone, determine what’s different and quicklymake the needed updates.”“Bill of Material creation is also automated,so I don’t have to spend a day compilingthat,” Brian explains. “We also save time byautomating a lot of repetitive tasks usingthe journaling and macro capabilities. I cando a task once, record it with journaling andsave it as a macro to use on my next projects, which can speed up the design processdramatically.”Mold manufacturing with NXJK Machining uses NX CAM to program allmilling operations involved in mold manufacturing. The company’s production facilityincludes two Milltronics machines that areused primarily for drilling cycles and roughing, and two high-speed Röders verticalmachining centers, one 3-axis and one5-axis, used for finishing mold cavities andcutting electrodes for electrical dischargemachining.The numerical control (NC) programmers atJK Machining work directly from the CADmodel of the mold and use NX design functions extensively to prepare models formachining and to design electrodes. TheCAD tools are used frequently to extrude,“NX Mold Wizard has simplified and automateddesign changes – when we get a revised partmodel we can just drop it in, add shrink,compare the old part to the new one,determine what’s different and quickly makethe needed updates.”BrianMold DesignerJK Machining
unite, and close up gaps. “There’s a lot ofhistory in the mold model that we can takeadvantage of,” says Rick, a senior programmer at JK Machining. “For example, if wewant to remove all the water lines or boltholes, we can do it with a single click.Synchronous technology in NX is very easyand intuitive. We use the optimize facecapability to heal questionable part geometry we get from customers, and it’s a lot easier than going through a multi-step healingprocess. We can easily move, replace, andoffset faces.”The fully integrated mold design andmachining of NX can save hours of time onmost projects. “We can easily edit in CAD,easily go back and forth between CAD andCAM,” says Mitch, a CNC programmer atJK Machining. “With our previous software,we would design a mold, export it from theCAD system, import it into CAM, and whenthings would go wrong, we would have todo it again.”The advanced NC programming capabilitiesof NX help make JK Machining more competitive. “With the capabilities of our oldsoftware, when we were shown a part, weoften doubted whether we could handle it,”Rick says. “But capability is not a questionanymore. We can address any challengenow – complex parts, deep pockets weknow we have the capability to programthem.”High-speed machiningHigh-speed machining is a key technologyfor moldmakers, because higher machinespindle speeds and feed rates can morequickly achieve milled surfaces with a nearmirror finish. “NX is tailored for high-speedmachining,” Rick says. “With automatic radiiand the approaches and exits of toolpaths, itlends itself to very fast and smooth cutterpaths. The machine can keep the RPMs andfeed rates high, while eliminating sharpcorners, sudden stops, and pauses on thesteel or graphite.”“The finishes are just awesome,” Rick continues. “Using the Röders machines we canachieve great surface finish on every job.When we get a mold machined, there’s nobenchwork needed. That saves a lot of time,and it improves the customer acceptancerate.”Easier 5-axis machiningJK Machining’s NC programmers especiallyappreciate the tool tilt controls in NX CAM,which make it easier to take advantage of5-axis machining. It automatically converts3-axis tool paths to 5-axis to efficientlymachine molds with deep cavities. Withtilted tools, JK Machining can use shortertools to reduce vibration, minimize tooldeflection and improve surface finish.“Without tool tilt, we would have to take thecutter to the grinder and relieve the neck,”Rick says. “When you’re cutting an electrodewith a .032-inch diameter cutter that’shanging out an inch and a half, you have toslow down the feed rate by a third and takesmaller cuts. Everything’s slower using thetraditional machining. But with the 5-axistool tilt method in NX CAM, we improvemolds quality while reducing machiningtime by up to four times.” Mitch likewiseappreciates the capability: “Tool axis tilt isunbelievable. It makes a world of differencein what we are able to do, and we can takeon a lot of projects now that we couldn’ttake on before.”Powerful, flexible, versatileNC programmingWith high levels of user control and manyoptions, the advanced 5-axis milling of NXgives JK Machining’s programmers greaterflexibility to maintain high feed rates andfine finishes. “The flow cutting method,which we use for rest milling, is just perfectfor mold machining,” Rick says. “Thereare so many options to get the right toolpath – you can start from the top or workyour way from the bottom; work outside-inor inside-out. We could not achieve thesame results with our previous software.With NX, we can always get a good cutterpath.”
Solutions/ServicesNXwww.siemens.com/nxCustomer’s primary business“With the 5-axis tool tilt method inNX CAM, we improve molds qualitywhile reducing machining time byup to four times.”JK Machining designs andmanufactures plastic injectionmolds. Since 1980, thecompany has served theautomotive, medical andelectronics industries.JK Machining specializes inhardened, inserted, closetolerance class 101 moldsand is ISO 9001:2000 certified.www.jkmachining.comCustomer locationKalamazoo, MichiganUnited StatesSolution Partner ProviderCAM Logic, Inc.www.camlogic.com“NX is tailored for high-speedmachining. With automaticradii and the approachesand exits of toolpaths, itlends itself to very fast andsmooth cutter paths.”RickSenior ProgrammerJK MachiningRickSenior ProgrammerJK MachiningAutomation saves time, improvesprogramming efficiencyNX includes many tools that JK Machiningleverages to automate and customize molddesign and manufacturing. Process templates help the NC programmers ensure theuse of proven cutting methods and tooling.“With process templates I never worry abouthaving to enter the same parameters forevery job, like the diameters or depths ofcut, or feeds and speeds,” Rick explains. “Ican re-use saved templates to kick out a toolpath in a matter of minutes, instead of anhour when I have to think about the depthand the side wall and the scallop size. Wehave a library of templates of provenmachining cycles, including roughing, semifinishing and finishing, so the NC programming is automated. It makes machiningmuch faster.”Customization tailors capabilities,automates repeatable tasksJK Machining also values the open automation and customization tools that enablethe company to tailor NX to its specificrequirements. “I like the way that NX supports different programming languages,”Rick says, “so if I’m writing a journal file toautomate repeated steps I can choose mypreferred language.” Creating machine-specific NC programs is another importantaspect that Rick appreciates: “When we gotthe 5-axis machine, I couldn’t modify thepostprocessor with the previous specializedsoftware. However, the NX Post Builder istotally open and I can easily tweak the post.Using the fine-tuned posts, we can get theright programs to make machining fasterand better.”Long-term successKalkman summarizes the impact that NXhas had on JK machining: “NX works flawlessly. We have been using the software fora long time and we’ve seen a lot of changesover that time. In the past we were justusing 3-axis machining and now we’re using5-axis machining. We are already lookinginto robotics to further automate the process. Automation and continuous improvements using NX helped us build ourreputation for delivering highest-qualitymolds on time. That’s how we stay competitive and grow our business.”Siemens PLM SoftwareAmericasEuropeAsia-Pacific 1 314 264 8499 44 (0) 1276 413200 852 2230 3333www.siemens.com/plm 2018 Siemens Product Lifecycle Management Software Inc. Siemens, the Siemens logo and SIMATIC IT are registered trademarksof Siemens AG. Camstar, D-Cubed, Femap, Fibersim, Geolus, GO PLM, I-deas, JT, NX, Parasolid, Solid Edge, Syncrofit, Teamcenter andTecnomatix are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in theUnited States and in other countries. Simcenter is a trademark or registered trademark of Siemens Industry Software NV or its affiliates. All other trademarks, registered trademarks or service marks belong to their respective holders.68664-A13 9/18 A
Mold design begins immediately when JK Machining is awarded a project. The com-pany makes extensive use of the specialized mold design tools of NX Mold Wizard to cre--ties, runners, cooling lines and other mold features. “Using NX is light years beyond
where the use of 5-axis simultaneous machining brings unequalled surface quality. Moreover, it is targeted at prototype machining, 5-axis trimming and special machining where full 5-axis machining is the requirement for quick and accurate manufacturing. Multi-Axis Surface Machining is also an add-on product to Prismatic Machining and Lathe .
There are different types of machining process used for sapphire material. The fig. 1 shows a graphical representation of sapphire machining processes i.e. laser machining process, grinding process, polishing process, lapping process, new developed machining process, compound machining process and electro discharge machining process. Fig.1.
Machining metals follows a predictable pattern with minimal creep. When machining plastics, quick adjustments must be made to accommodate substantial creep — not to mention that the material has a strong propensity for chipping and melting during machining. Simply stated, the basic principles of machining metals do not apply when machining
Machining metals follows a predictable pattern with minimal creep. When machining plastics, quick adjustments must be made to accommodate substantial creep — not to mention that the material has a strong propensity for chipping and melting during machining. Simply stated, the basic principles of machining metals do not apply when machining
PCI Machining - Absolute Machine Tools 7944 Innovation Way Mason OHIO 44053 USA 1 (513) 701-5550 sales-usa@pci-machining.com PCI Machining Rue Copernic 42030 - Saint-Étienne FRANCE 33 4 77 42 60 88 sales@pci-machining.com services@pci-machining.com PCI Machining Vertriebsbüro Deutschland Lebacher Straße 4
The milling machining is limited to the XY plane and can thus follow 2-dimensional contours. The machining itself is limited to 2-dimensional contours. The third dimension is achieved by tilting and securing the machining plane. To machine the free -form surfaces, the 5 axes move dynamically and simultaneously. 2D machining . 2½D machining
01 GT Series 5-axis Machining Center GT Series 5-axis Machining Center 02 GT Series GT Series is developed for aerospace, mold, and automotive parts machining. According to the machining requirements, 15,000/ Gantry type structure, the control of three linear axes, wihch are
the high performance machining envelope fo r a CNC machine is described. A student-implemented case study of this methodology resu lting in significant pe rformance gains of machining an automotive part is presented. Introduction Current machining methodology is largely experien ce-based in that much of the knowledge has
