Press tool maker automates the job

With the help of Open Mind's Hyperfact CAM software, High Wycombe press tool specialist JP Engineering (HW) is able to develop CNC part programs automatically from tool designs.

With the help of Open Mind's Hyperfact computer-aided manufacturing (CAM) software, High Wycombe press tool specialist JP Engineering (HW) is able to develop CNC part programs automatically from tool designs.

Previously, manual programming time was typically 2.5h, but the new software has reduced this to less than 10min - a staggering 15-fold time saving.

According to JP Engineering's owner, Jeff Bulpett, Hyperfact has provided a significant step forward in efficiency, quality and competitiveness.

He says: "In the current climate we have to maximise productivity to achieve tighter turn-around time on tooling.

Eight weeks is now a standard requirement, particularly from the white goods sector.

This gives us very little room for manoeuvre in the tool design and manufacturing process".

He continues, "The capability to automate CNC program preparation for drilling, boring and tapping guarantees that those programs will be available as required.

It also assists smooth progression of projects through the factory, as tool assembly is more reliable.

In addition, it reduces the workload on the programming personnel.

Whereas we used to have two people engaged in programming to support double-shift working on our machining centres, we now achieve the same output with one person, freeing the other to perform different tasks".

JP Engineering (HW) is a leading designer and manufacturer of progression tools and single-stage tool sets for use on transfer press lines.

The company supplies tooling to OEMs and first tier suppliers in a number of industry sectors.

In recent years the emphasis has shifted away from electronics to white goods and automotive components manufacture.

Historically, most of the tooling it manufactures has been for production of two-dimensional 'stamped' components with some bending and folding.

However, entry into the automotive supply sector has seen increased need for tooling capable of producing three-dimensional forms.

Tool development begins with the design for the finished product.

Despite the dominance of CAD in the design process, JP Engineering (HW) Ltd receives a high proportion of component data as 2D drawings.

From this information, the company develops a breakdown of the process by which the component will be manufactured and this provides the basis of the tool design.

IT Manager Alan Jordan explains: "In general we produce progression tools up to around 1200 x 800mm in size, though in the past we have made tooling up to 2.5 x 1m.

Depending on the process design and complexity it may or may not be developed using CAD; however the actual tooling is always developed using our CAD system".

The predominant requirement for 'stamped' components has meant that a 2D package was most appropriate for the company's design requirements.

In simplistic terms, press tooling is built up on upper and lower bolster plates using machined or wire eroded tooling components that are machined separately.

Location of the components is achieved via a combination of dowelled alignments and bolted fixings.

This demands that a large number of accurately positioned holes be drilled, tapped or bored.

"Before we installed Hyperfact, programming these operations was carried out using an off-line version of the software used on our machining centres", says Jordan.

"However it was a labour intensive exercise.

Although we could make use of macros for the machining cycles, the position and depth data and the machine-related tooling information had to be input by the programmer.

On some of the bolster plates we have scores of holes so it took a long time to define the data and there was scope for errors.

A hole or a tapping operation might be omitted, for instance".

The company attempted to develop its own software to address the problem, but considered that its long-term potential was limited.

Jordan continued: "What we wanted was a system that could automatically recognise round hole-type features from the 2D design and develop the 2.5D program necessary to machine them using the data contained in the model.

However, we recognised the need to install a system that was capable of being developed in the longer term to support milling procedures for 3D work".

The attraction of Hyperfact was that it appeared able to offer JP Engineering (HW) the immediate solution that it needed, while Open Mind is committed to further developing the system for general milling work.

Importantly it is supported by Open Mind premier reseller, Toolbox, also based in High Wycombe, which supplied and installed the software and supplies local help, advice and training.

At JP Engineering (HW) the system is configured to operate with a library of 84 tools which are resident on, or available to, the company's machining centres.

The company's tool designers are constrained to define hole specifications that can be produced using these tools.

The tool library and other procedural data were defined by JP Engineering (HW) as part of the system setup.

The key operational procedure within Hyperfact is a feature list convertor that directly transforms the 2D CAD system output into co-ordinates and specifications for all of the holes that need to be machined.

These data are used to select the tools required to complete the hole making operations using company standard procedures.

It then applies to the tooling macros parameters gleaned from the feature list - principally hole depth as measured from the material surface.

Routines within the software identify groups of identical holes to maximise machining cycle efficiency.

Hyperfact is capable of detecting and highlighting features for which tooling has not been defined, providing the opportunity for suitable tooling to be added or for the feature to be redefined.

When a tool is added on Hyperfact, the tool library available to the designer is updated simultaneously.

Although JP Engineering (HW) has standardised on 84 tools, this suite divides between 'preferred' tools and 'others' so that the need to exchange tools into the machining centres' magazines is minimised.

Provided that the component is designed in accordance with laid-down guidelines, generation of the CNC program is very rapid.

In practice there is often a need to adjust the design and/or the program.

Nevertheless, savings in CNC program preparation time are typically in the range 65 to 75% on 'hole only' components such as bolster plates.

On parts where a significant amount of milling work is needed the advantage is less, depending on the complexity of the milling task.

On stamping-type press tools, a high proportion of components are machined using wire EDM which is programmed using a separate CAM system.

JP Engineering (HW) also operates a high technology EDM drill, used for producing high aspect ratio, small diameter holes.

As the company has begun to take on more motor industry work, however, there has been an increased requirement for generation of 3D forms.

Initially the company subcontracted this work but the regularity of the requirement increased, leading directly to installation of Open Mind Hypercad and Hypermill CAM software.

These are operated independently from Hyperfact.

All the systems win praise from Jordan for the intuitiveness of the interface, the excellence of the file conversion software and the capabilities of Hypermill's collision avoidance routines.

"Hyperfact has been the most widely applied of the Open Mind systems that we have installed", he concludes.

"However, there is a lot of potential for development of the Hypercad 3D design application, coupled with Hypermill.

It has already proved very useful on certain motor industry projects where there is a need to generate quite complex forms in the progression from flat strip to finished component.

"Increasingly we are called upon to participate in development of the component so availability of a powerful 3D CAD system is essential, as is the capability to transform those designs into metal.

Given the efficiency gains from using Hyperfact on 2.5D work we would certainly be keen to see the principles extended to 3D machining in the future".

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