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The automotive industry is renowned for demanding ever faster turnaround times and tighter tolerances. To meet such demands, Clacton-on-Sea subcontractor Tridan Engineering has made EDGECAM a major part of its manufacturing processes.
EDGECAM programs a total of 16 Mazak CNC machines, of which six are 5-axis, including a Variaxis i-500 with a Palletech automation system. It is with the 5-axis work that EDGECAM is proving particularly valuable. One of the biggest challenges facing their production process is keeping up with ever-changing tooling. Commenting upon this, Tridan Engineering\u2019s Machine Shop Manager, Mr Paul Coupland says: \u201cWe manufacture a range of automotive components, mainly for Ricardo, along with some F1 test parts. We work with two main tooling suppliers, ITC and ISCAR, they are both improving their tools all the time. EDGECAM provides us with the optimum machining strategies every time the cutting tool is updated. For example, we produce a number of gearbox transmission systems for Ricardo, and some diff cases for world rally cars. We\u2019re currently working on a rear differential case for an off-road race car.\u201d
\u201cEDGECAM programs all our machines to their absolute top tolerances \u2013 we regularly have a 2-micron tolerance on most of our jobs, and we can guarantee that they\u2019re manufactured to that required high precision every time.\u201d
The CAM software\u2019s powerful Waveform Roughing Strategy has been a major influence on the Essex Company and how they machine their automotive components. Everything is now done with the Waveform trochoidal milling and tooling strategies to take full flute length cuts and optimise tooling performance. Lead Production Engineer Mark Proctor says they\u2019ve had some spectacular results with it, but admitted they were at first nervous about the prospect of ramping up feeds and speeds and using the full flute length. \u201cWhen we were told we could machine a piece of S143 stainless steel at eight metre a minute, we thought the cutting tool wouldn\u2019t last two seconds.\u201d
But he says once they saw the resulting faster cycle times, and that the tool was safe from damage, they made the decision to do all their Waveform roughing at the machine\u2019s fastest feed rate. \u201cFor instance, we needed a finished component that\u2019s only 20mm thick, coming from a six-inch S143 round billet. That means there\u2019s an awful lot of metal to cut away. For that job we used a 12mm cutter for a 24mm depth of cut at a feed rate of just under nine metres a second, and the job ran for ten hours before the cutting tool needed replacing.\u201d
Tridan ships around 9,000 parts a month to customers around the world \u2013 anything from small components to workpieces up to 1.6 metres, both as single units and in large batches. Almost every automotive part they produce goes through EDGECAM.
\u201cWhen we get the model from the customer, normally as a STEP file, we load it into EDGECAM, select the stock, devise the machining strategy, add the tools and toolpaths, and run the program through the simulator. When it comes through that, we use the NC editor to post the program out to the machine via a DNC wireless link, and explain the job to the operator. He then goes to the shopfloor with a setup sheet that shows which tools he needs, and runs the machine.\u201d
Mark Proctor says EDGECAM is even better since it included a button to unhide the stock underneath. \u201cIn earlier releases it wouldn\u2019t see the stock underneath, but it\u2019s now an even better cycle with this option.\u201d Describing 5-axis machining and automation as the way forward for Tridan Engineering, Paul Coupland says their recent acquisition of the Mazak Variaxis with a Palletech automation system adopts both of those aspects. \u201c5-axis is definitely the future for us, as it enables us to machine much faster than 3-axis can, through the \u2018Done In One\u2019 capability, without the need for additional set-ups. And the automation system on the Variaxis can manage six pallets, which is perfect for our needs. We can add six pallets at any stage of the operation to keep it going. It also means we can carry out lights out machining. Depending on the job, it can run constantly for between eight and 14 hours without any manual intervention.\u201d
Currently operating from 26,000 square foot premises with 66 employees, growing order books mean the company, which was founded in 1968 and now owned by the Langham Group, are now looking to take what he describes as their next natural step. \u201cWe\u2019ve recently bought a third of an acre next door, and are planning to double the size of our machine shop.\u201d