Going for Gold! Achieving Precision Machining Excellence: A Step-by-Step Process

Manufacturing embarked on an exciting journey into the world of precision multi-axis machining. Using advanced technologies from GROB machine tools, Lang work holding, and Emuge Franken tooling, all orchestrated by SolidCAM software, we set out to create a trophy worthy of winners.

Step 1: Setting Up the GROB G350 Machine Tool

When multi-axis machining at high volume, a highly capable machine tool is a must, and with the GROB G350, we have exactly that.

Proving itself to be a real asset when working on this project, the G350 has the ability to invert the table and having a horizontal spindle, it is a great combination of versatility and rigidity.

It allowed us to have a large reach and work around multiple pieces of stock.

Machine Preparation

Selection: Choose the GROB G350 for its high acceleration, efficient chip management, and robust tunnel setup, ideal for high-volume, multi-axis machining.

Calibration: Ensure the machine is properly calibrated and ready for precise operations.

Setup: Prepare the workspace and verify all machine settings.

Step 2: Implementing Lang Technik Clamping Solutions

Next is the implementation of Lang Technik’s pioneering clamping pyramid, which allows simultaneous access to all five faces of three parts.

This setup not only increases productivity, but also minimises tool changing time.

The zero-point fixture system ensures accurate and repeatable positioning – a key factor in maintaining precision throughout the machining process.

Fixture Design and Installation

Clamping Solution: Utilise Lang Technik’s pyramid clamping systems to access all five faces of three parts simultaneously, increasing productivity.

Zero-Point Fixture System: Implement the zero-point fixture system for accurate and repeatable positioning, crucial for maintaining precision.

Setup: Secure the Lang Technik clamping system on the GROB G350 machine.

Step 3: Selecting and Setting Up Emuge Franken Tooling

With the machine and fixtures in place, the next focus is tooling.

Emuge Franken’s Franken Alu-Cut range, known for its accuracy and precision, is a perfect fit for this project.

The use of standard off-the-shelf solutions makes Emuge Franken the ideal tooling partner for our trophy project, providing reliable tooling options without the requirement for custom designs.

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Tool Selection and Preparation

Tool Range: Choose tools from the Emuge Franken Franken Alu-Cut range, known for precision and reliability.

Standard Solutions: Use off-the-shelf tools to meet the specific requirements of the parts, avoiding the need for custom designs.

Tool Setup: Install and calibrate the selected tools on the machine, ensuring they are ready for the machining process.

Step 4: Integrating SolidCAM Software

SolidCAM software plays a pivotal role in this process – connecting everything together by integrating data from the machine, fixtures, and tooling.

SolidCAM applies tool paths, digitally simulates machining, and optimises processes to ensure the best quality parts.

The software’s patented iMachining technology enhances material roughing efficiency, while barrel tools help achieve high-precision surfaces, maximising the performance of the entire setup.

CAM Programming and Optimisation

Data Integration: Input data from the machine, fixtures, and tools into SolidCAM.

Tool Path Application: Use SolidCAM to apply precise tool paths based on the integrated data.

Simulation: Digitally simulate the machining process to identify and resolve any potential issues before actual machining begins.

Optimisation: Utilise SolidCAM’s patented iMachining technology for efficient roughing and high-precision finishing.

Step 5: Executing the Machining Process

Set up complete – the machining can begin. The GROB G350, equipped with Lang’s fixtures and Emuge Franken’s tools, operates under the guidance of SolidCAM’s optimised tool paths.

Machining Execution

Machine Operation: Start the GROB G350, equipped with Lang’s fixtures and Emuge Franken’s tools, and execute the machining process as guided by SolidCAM.

Versatility and Rigidity: Take advantage of the machine’s ability to invert the table and use a horizontal spindle to handle complex geometries and multiple pieces of stock.

Conclusion: The Power of Integration

“Now with our finished part, you can see how the right tooling can make all the difference to the success and the quality of a job, along with using the right tool and the right application to optimise cycle times every step of the way.”
Will Kearse – Technical Engineer, Solid Solutions

This comprehensive approach, integrating advanced machine tools, innovative fixturing, precise tooling, and sophisticated CAM software, demonstrates how complex parts can be machined precisely and efficiently.

Together with our key industry partners, Solid Solutions Manufacturing is well positioned to provide turnkey solutions for machining.

The collaboration between GROB, Lang Technik, Emuge Franken, and SolidCAM showcases the potential of manufacturing technologies to produce high-quality parts, optimising every step of the process for maximum efficiency and precision.