Software keeps shop online: Turning Performance

By CNC Software Inc.

Several decades ago, after years of working as a machinist in his home state, Ohio native Sam Roberts decided to head south in search of manufacturing career opportunities. Weary from his 80-mile commute, he was ready for a change of scenery — and climate.

“I took the chance and drove to Georgia on my last paycheck and a prayer,” he said. “I baked cookies on Highway 5 in Douglasville for a couple of weeks until I found a manufacturing job.”

Through that job and a few others, Roberts honed his manual and CNC machining skills. In 1999, he was introduced to MastercamCAD/CAM software from CNC Software Inc. in Tolland, Connecticut. As a machinist proficient in G code, he was impressed with the software.

“When I saw Mastercam and had an opportunity to see what it could do,” he said, “I thought, ‘Wow, that’s impressive. That’s a lot better than typing in G code all day.'”

3D-Machine employee Bryan McKinney is pictured with a hoist drum. The part groove was machined on a vertical turning lathe with Mastercam’s Lathe Custom Thread toolpath. Image courtesy of CNC Software

In 2001, Roberts seized a chance to run his own machine shop. Armed with Mastercam version six and a Haas VF-3 vertical machining center, he launched 3D-Machine Inc. Located more than 20 miles northwest of Atlanta in Powder Springs, the full-service shop specializes in precision milling and turning of parts ranging from less than 28 g (1 oz.) to 13,608 kg (30,000 lbs.). Industries served include hydropower and nuclear power, automotive, aerospace, communications and medical.

Over the past 20 years, 3D-Machine has grown at a steady clip. The original 111-sq.-m (1,200-sq.-ft.) facility expanded to 3,530 sq. m (38,000 sq. ft.). A larger space means more employees — currently numbering just under 20 — and bigger machinery, including a horizontal boring mill, lathes and vertical turning lathes.

“I’ve got enough room to grow,” Roberts said. “We do a lot of shaft work, some pump work. We really do anything. If we think we can do it and not have to charge a crazy amount to make the part, we are not afraid to take something on. We’ll do whatever it takes.”

More than 20 years after his first encounter with his favorite CAD/CAM software, he still relies on it for his design and production needs. 3D-Machine stays current in Mastercam by using the latest release, which features Mastercam Mill, Mastercam Lathe, Mastercam Wire and Solids. In addition, the company participated in the beta program for Mastercam 2021. He appreciates the generous selection of toolpaths in the software.

“I recently discovered a new toolpath called Lathe Custom Thread,” Roberts said. “It is phenomenal.”

The toolpath supports custom thread forms and expands support for modeling chucks and chuck jaws. The CAM software supports collet chucks as individual component types, which extends the range of machines that can be supported directly. The toolpath also streamlines and simplifies programming workflow.

By selecting chained geometry in Lathe Custom Thread, a programmer can choose the thread cross section or one of the following parametric definitions: rope, buttress, square or trapezoidal. The toolpath includes Mastercam Mill-Turn simulation enhancements, as well as support for select Swiss machining.

A close-up view is given of a hoist drum groove being machined on a vertical turning lathe programmed with Mastercam’s Lathe Custom Thread toolpath. Image courtesy of CNC Software

3D-Machine recently produced a carbon steel part for a cable reel. The part had a 23.8125 mm (0.9375″) pitch and a 10.312 mm (0.406″) radius. A 12 mm (0.4724″) button tool was used to rough and finish the part. Because the company created the chain, deburring occurred during the process.

The part, a hoist drum, employs a wire rope or cable to lift or lower loads. The grooves keep steel cables from overlapping, which could damage them, and prevent inconsistent lifting and lowering of objects. Due to its size, the drum was machined on a large vertical turning lathe. The selected toolpath is not limited to vertical machining and just as easily can be performed on a horizontal lathe. In this case, the machinist cut a left-handed spiral, so the tool engaged in the cut from the bottom to the top to produce the shape.