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of Mastercam and Productivity+ were released in 2015, almost all of the rough edges we noted in the fi rst version were gone. We established a goal of implementing it on all of our Mazak fi ve-axis machining centers for our complex fi ve-axis machining operations, as well as on our three-axis mills and large VTL. ADEX embarked on a one-year


R&D project to apply the new technol- ogy across the Aerospace, Defense, and Energy facets of our business. We envisioned the potentially enormous benefi ts of in-process gaging and made it a business priority. We enlist- ed our Mastercam Reseller, Barefoot CNC, as a partner in this project. They co-developed and installed a post for Productivity+, leveraging substantial programming and testing support from Mastercam’s Manufacturing Lab in Tolland, CT. Barefoot also trained our CNC programmers and machinists in appropriate use of the gaging software and the post.


In October 2015, the fi ve-axis machining programs with in-process gaging were proven to our customer’s overwhelming satisfaction on three of our fi ve-axis Mazaks. In one particu- lar case, 75% process downtime has been eliminated by automating in-process gaging. We have estimated there will be a 25–40% improvement in productiv- ity as well as 100% product acceptance as in-process gaging is implemented on many of the details and assemblies run- ning across all of our fi ve-axis machining centers, three-axis mills, and large VTL with live tooling. In Conclusion: Many aerospace shops don’t allow their en- gineers and machinists enough time to do research and devel- opment. They want their parts cut and shipped right now. The owners and managers have the philosophy of “we don’t have time for that, we’ll do it later.” Just the few examples cited above demonstrate why it is so important to understand the importance of R&D and spending time just learning. We give our engineers and machinists the time to experiment, dream, and brainstorm in order to make the impossible become the possible. Some of those things are helping us carve huge productivity gains out of our manufacturing operations.


Massive amounts of material must be removed from billet parts like these without damaging or distorting thin walls. Mastercam’s Dynamic Motion technology accomplishes this by intelligently altering cutting tool motions based on material conditions ahead of the tool. This approach maintains a constant ideal chip load


for the highest possible material removal rates without stressing the part or the tool. Above, Dean Shaffer-Johnson, CNC Programmer.


in the weeds, we are learning many interesting things about specifi c ways to apply these new and emerging CNC manu- facturing technologies to tasks that were previously diffi cult, if not impossible. If your shop takes a little time to learn and experiment, you will discover some of these things yourself. In the meantime, we are not telling. They are our competitive advantages. Be inspired to go out and fi nd yours.


ADEX Machining Technologies is a one-stop supplier of precision CNC machined components and assemblies for the Aerospace, Defense, and Energy industries. ADEX provides expertise in complex tight tolerance fi ve-axis milling and large part turning with an emphasis on hard metals and super alloy materials. Coupled with OEM approved secondary partner relationships, ADEX offers cost-effective supply chain solutions enabling its customers to compete in today’s challenging global marketplace.


127 — Aerospace & Defense Manufacturing 2016


That is the macro approach that we want to share, in order


to promote an outlook that can put manufacturing businesses in the USA on an upward spiral of robustness and health. There is also an important smaller picture that, for proprietary reasons, we choose not to say anything about here. Down


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