SHOP SOLUTIONS
Until that time, the company was mostly making parts on a two-axis lathe and three-axis mill, which were pro- grammed conversationally at the machine. To take advan- tage of all of the capabilities the Integrex fi ve-axis machine
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offers, the company needed a CAM system for off-line programming. After surveying the marketplace, Sham- rock purchased a seat of Mastercam Multiaxis CAD/CAM software from CNC Software Inc. (Tolland, CT). Program- mer Henry Lopez said, “I was already familiar with Mastercam from my experience working with it at another shop, and I knew I would be able to take programming off-line to work in fi ner detail, particularly contours, while reducing run times.” The small products—1” long by 3/8” (25 × 9.5-mm) diameter—made on the lathe side of the shop were being manufactured in high volumes of up to several hundred thousand a month. “On the Integrex side of our shop, there are a lot of prototype parts that other companies don’t quote because they are too diffi cult,” said Adair. “We use Mastercam for the challenging ones. They are 3D, have holes going in at different angles, and either have slots in them or a lot of cutouts.” Fortunately, most of the initial jobs that came for the fi ve-axis machine involved positioning the head for three- axis work in a variety of angles with just a single setup. This was not a stretch for Lopez, who was already adept at three-axis work in Mastercam. When more complicated work came up he knew he could always call or send an e-mail to MLC CAD Systems, his local Mastercam reseller, for a prompt solu- tion to his problem. One of the fi rst things the reseller advised him to do was to investigate a variety of toolpaths incorporating Mastercam’s Dynamic Motion technol- ogy. The software has a sophisticated, material-aware algorithm that continu- ally adjusts the speed and engagement of the tool based on actual material conditions ahead to reduce machine cycles, tool wear, and breakage.
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