Unmanned machining with confidence

END USER: Van Riet Metaalbewerking BV, +31-497-591303, www.vanrietmetaalbewerking.nl.
CHALLENGE: Eliminate part deviations when performing lights-out machining.
SOLUTION: CAM software with the properly adjusted post-processor for automatically measuring parts on a machine tool.
SOLUTION PROVIDER: DP Technology Corp., (805) 388-6000, www.dptechnology.com.

When performing lights-out manufacturing, Ad van Riet, owner of Van Riet Metaalbewerking (Metalworks) BV, wants to know that mistakes aren’t being made in the dark. The eight-person company makes mechanical parts, including prototypes and production parts, typically from steel and nonferrous metals.

Based in Veldhoven, The Netherlands, Van Riet invested in a Mazak Variaxis 630-5X II 5-axis machine tool with an automated pallet system to increase part accuracy and reduce errors by decreasing manual operations. In addition to streamlining production processes, Van Riet cut labor costs and increased production by running the machine unattended for 18 to 20 hours a day.

Courtesy of DP Technology

Foreman Bart van de Sande (left) and Owner Ad van Riet in front of Van Riet Metalworks’ Mazak Variaxis 630-5X II 5-axis machine tool.

To drive the machine tool, Van Riet purchased ESPRIT CAM software from DP Technology Corp., Camarillo, Calif. ESPRIT reseller Pimpel Benelux provides local support.

Embarking on its unattended machining mission, Van Riet created an automatic measurement cycle within the CAM package, reflected in the machine tool’s post-processor, so deviations from part dimensions can be automatically modified.

“When we arrive in the morning, we can be assured the parts are correct,” van Riet said. “So even when a tool wears, we don’t worry because any deviation is automatically corrected. The moment the sizes fall outside the tolerance, the controller automatically goes back to the starting line of the operation and the operation is done again.”

For example, if a measurement probe detects a hole is too narrow, which indicates extensive tool wear, the drill is automatically replaced. If a measurement is out of tolerance to the extent that correction is impossible, the operation is aborted.

In addition to the automatic QC processes, Foreman Bart van de Sande goes a step further by measuring completed parts at random. “With intense usage, tool inaccuracy increases, but with the on-machine measurement probe you don’t see any deviation in the measurement results,” he said.