Autodesk Fusion for Manufacturing enhances accuracy, reduces setup time, and improves efficiency in CAM programming with advanced probing, inspection, and alignment, empowering manufacturers to achieve higher precision and productivity.

In the ever-evolving landscape of manufacturing, precision and efficiency are paramount. Autodesk Fusion for Manufacturing enhances the accuracy of manufacturing processes and streamlines CAM programming. Ultimately, making it easier for manufacturers to produce high-quality parts.

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Lets delve into these capabilities, how they work, their impact on production, and how to access Fusion for Manufacturing.

What are probing, inspection, and part alignment?

Probing

Probing is a process used in CNC machining to measure the dimensions of a part or its features. It involves using a probe. This is typically a spindle-mounted device, to physically touch the part’s surface to gather data about its geometry. You typically compare this raw measurement data against a 3D CAD model or another predefined ideal to determine deviations. These measurements confirm if the part is within tolerance or if you need to take corrective steps.

Inspection

Inspection refers to the process of examining a part to verify that it meets the required specifications. This can involve various techniques, including visual inspection, dimensional measurement, and surface analysis. Inspection often uses spindle-mounted probes and other devices like Bluetooth-enabled calipers.

Part alignment

Part alignment is the process of positioning a part accurately on a CNC machine prior to the machining process. This process can be applied to any size and shape of parts. However, it’s most advantageous for aligning large, heavy, or difficult-to-align components using manual dial-test indicators. Examples could be castings, forgings, or 3D printed parts with complex, organic shapes and limited flat faces or straight edges.

Typically, you run a probing program on the CNC machine to capture measurement data, then import this data into the Fusion for Manufacturing software to compare it against the original CAD model. Algorithms can determine deviations and calculate the necessary translations and rotations to align the 3D CAD model with the part’s position on the machine. Apply this re-alignment map during subsequent CNC machining operations to ensure they align with the physical component and achieve dimensional precision.

How do probing, inspection, and part alignment work?

The workflow for performing part alignment using probing and inspection in Autodesk Fusion for Manufacturing is straightforward yet powerful. Here’s a step-by-step overview: 

1. Create a milling setup: Start by setting up a milling operation and defining the necessary manufacturing steps for machining the part.

2. Specify transformation type: Choose the type of transformation for part alignment in Fusion. This determines the number of axes available for translating and rotating the part, varying based on the component and the machine’s capabilities (e.g., a 3-axis vs. a 5-axis machine).

3. Generate inspect surface operation:  Identify the points on the part’s surface that need probing. These points can be specified using pre-defined patterns or by manually selecting points on the 3D model.

4. Export machine specific NC code: Export the probing program as NC code using a post-processor tailored to the specific CNC machine functions. The NC programs record the spindle-mounted probe’s precise location upon contacting the part. The post-processor will vary depending on the controller type and probe used.

5. Run NC code on CNC machine: Execute the NC code on the CNC machine equipped with the spindle-mounted probe. Running the program generates a text file with data, including date, time, and inspection measurements, which can be copied from the CNC machine.

6. Import inspection results: Import the inspection data into Fusion. Fusion uses this data to calculate the necessary rotations and translations to align the machining process with the physical part.

7. Post-process remaining operations: Use the calculated part alignment to post-process the remaining manufacturing operations. 

8. Transfer the programs to the CNC machine: The unique NC programs can now be transferred to the machine and executed. 

Impact on CAM programming

The integration of probing, inspection, and part alignment has a profound impact on CAM programming. Here are some key benefits: 

• Enhanced accuracy: By using probing and inspection data to align parts accurately, manufacturers can significantly reduce machining errors and improve product quality. 

• Reduced setup time: Automated part alignment reduces manual positioning time and effort, leading to faster setup times and increased productivity.

• Improved efficiency: The ability to perform in-process inspection and alignment allows for real-time adjustments, reducing the need for rework and ensuring that parts are machined correctly the first time. 

• Reduced non-conformance: By including probing and inspection steps throughout the machining process it is possible to monitor part accuracy at key stages of production. If problems start to appear it is possible to take corrective steps before parts are scrapped. In addition, if a part is found to be unsalvageable, manufacturers can decide to cease processing that specific part. This helps to avoid wasting any further time and resources on scrap parts.  

• Streamlined workflow: The seamless integration of these capabilities within Fusion simplifies the CAM programming process. This makes it easier for manufacturers to create, control and execute complex machining operations. 

How to access probing, inspection, and part alignment

Customers can access the probing, inspection, and part alignment capabilities by subscribing to Autodesk Fusion for Manufacturing. You’ll gain access to the full suite of manufacturing tools within, including advanced CAM programming tools, multi-axis machining, sheet-based nesting and fabrication, and metals-based additive manufacturing. 

The subscription is available for 1- and 3-year terms, providing flexibility to suit different business needs. Additionally, Autodesk offers a 30-day trial that contains all of the manufacturing functionality, allowing customers to explore its capabilities before committing to a subscription. 

Conclusion

Autodesk Fusion for Manufacturing’s probing, inspection, and part alignment capabilities are game-changers in the world of CAM programming. By enhancing accuracy, reducing setup time, and improving efficiency, these features empower manufacturers to achieve higher levels of precision and productivity. With the flexibility of subscription options and a comprehensive suite of tools, Autodesk Fusion for Manufacturing is the ultimate solution for modern manufacturing needs.