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FÉMALK – CAM Application to Increase Efficiency

FÉMALK – CAM Application to Increase Efficiency

Customer challenge

Fémalk Zrt. is one of the leading Hungarian suppliers of cast aluminum components for the automotive industry. As expectations are increasing from year to year, continuous improvement and optimization are required in every step of the production process. Therefore, it was also necessary to enable a reduction in time and improvement in reliability of the production engineering of the casting moulds.

Project goals

The company has been using the Autodesk PowerShape/PowerMill solutions for many years, so the following improvements have been made to speed up the tasks that emerged during the usage of them: 1) Development of an automatic tool database creator, which automatically creates and updates tool geometry and cutting data based on manufacturer data. 2) Development of an NC setup sheet creator application with a graphical user interface to accelerate the error-free creation of manufacturing documentation. 3) Development of a unique NC program datasheet that, while maintaining the format already used by the company, calculates and displays data that increases the reliability and reduces the necessary time of the sub-activities required for production.

Solution

The production of moulds involves working with milling tools with a wide range of geometries from several suppliers. Each supplier provides the tool’s geometry and cutting data in different data formats. Keeping the database used in the CAM system accurately up-to-date is a time-consuming task, which can be flawlessly performed by the developed automatic data upload application. A lot of data has to be entered manually during the creation of NC setup sheets. The developed NC setup sheet generator application automatically uploads a significant part of the data and provides a simple user interface for manual data entry too, making the process of document creation more reliable and faster. The enhanced NC setup sheet retains the same format as previously used by the company. It calculates and displays additional data to speed up the process of ordering the right type and quantity of milling tools for each project expedite post-calculation of cost.

Business outcome

By using the applications developed for PowerMill, the acceleration and improved reliability of the production engineering process have made the whole process more efficient, so the optimization has significantly accelerated the work of CAD/CAM technologists, contributing to the company's development and retrenchment program.

Conclusion

If attention is paid to the optimization of each part in the whole production process, and to the relationships between the individual parts, the expected result will not fail behind. During the development tasks, we have taken into account the possible usage of a given element (e.g. NC setup sheet) in several, other departments, so we’ve greatly contributed to the increase of the manufacturing process efficiency.

Project summary

    Duration & delivery

  • 180
  • 2021-06-15

    Autodesk solutions

  • PowerMill

    Services provided

  • Post Processor Development
  • Technical Support
  • Custom Application Development

    Customer industry

  • Subtractive Manufacturing
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