Optimization for hire: Turning Performance

By CGTech Inc.

As a CNC programmer for the proposal engineering department at Ingersoll Cutting Tool Co. in Rockford, Illinois, Mike Gampetro spends his days improving machining processes for customers. There could be an Inconel part for which he suggests ways to increase tool life, or it might be a long runner where every second of cycle time counts. No matter the situation, his job is to generate ideas that his customers can use to produce more parts in less time — and hopefully reduce operating costs along the way.

His company, which does business as Ingersoll Cutting Tools, helps machine shops of all sizes. One of the tools that provides no-cost assistance is Vericut toolpath simulation software from Irvine, California-based CGTech Inc.

“In most cases, a customer sends me their Vericut file and hopefully the NC program together with a tool list,” Gampetro said. “I’ll look at the existing metal removal rate, the cycle time, and make recommendations on how they can improve the process.”

CNC Programmer Mike Gampetro looks for better ways to machine parts. Image courtesy of Ingersoll Cutting Tools

He often needs to reprogram a job from scratch. When that happens, he runs a comparison between his revised cycle time and the legacy program. Vericut validates his recommendations. When done, he sends a revised tooling list, along with screenshots of the process, to the customer. If it has Vericut — he said most clients do — he includes a Vericut file in the package as well.

The results are worth the effort. Gampetro is able to reduce most cycle times by at least 15%, with some enjoying 50% or greater improvement. Although he is unable to share any customer names, he noted that a well-known manufacturer of aerostructures in the Seattle area was one of the latter examples.

“Some of our customers are producing very large, complex parts with cycle times of 40 hours or more,” he said. “Even a modest improvement pays huge dividends in these instances.”

Gampetro has been in his programming position for several years, but his experience with Vericut goes back far longer. He started as a production programmer for Ingersoll Cutting Tools in 1991, and the company has used the toolpath simulation software at its own shop for more than two decades.

“We have extensive capabilities here and machine a wide range of complex geometries, everything from indexable turning and milling tools to special-purpose cutters for automotive transfer lines,” he said. “Every single job is run through Vericut before being released to the shop floor to verify there won’t be a crash and that we have the best cycle time possible.”