CAD/CAM Part II

Part 1 of this in-depth look at CAD/CAM from industry experts appeared in the March 2012 issue of Today’s Medical Developments. The experts had so much to say that we are pleased to bring you the rest of their thoughts and insight into the CAD/CAM industry in Part 2.

TMD: Regarding CAD/CAM technology, what was the biggest advancement in the past five years?

Picklo: [The biggest advancement has been] automation and flexibility of software to meet the customers’ process with tools to handle engineering changes and concurrent engineering.

Mund: We have seen a huge advance in smart toolpaths – toolpaths that dynamically adapt to the shape of the part, adapt to what cuts are coming up, and/or adapt to what cuts were already made.

McMinn: A number of advancements to machine tools have affected advancements in CAD/CAM technology during the last five years, in particular 5-axis and multi-tasking machines. However, the biggest technology change in software in general has been the development of multi-threading. This is the ability of an operating system to execute different parts of a program, called threads, simultaneously, which effectively doubles productivity. With some systems, the programmer must carefully design the program in such a way that all the threads can run at the same time without interfering with each other. With our system, you can prepare, calculate, or edit toolpaths in the foreground while calculating other toolpaths in the background, with minimal degradation in processing speed. This is what we term background processing. It works on any hardware system but the benefits are greater on multi-core machines. The unique advantage Delcam has is that parallel processing can be used in both foreground and background calculations simultaneously. This will undoubtedly provide greater performance and greater productivity, and facilitate more experimentation off the shopfloor so that they can get optimal efficiency with their machines.

Mathews: Within the realm of CAD/CAM technology, the most significant advancements within the past five years are the ability to program, much easier, complex multi-tasking machines, and parallel process algorithms that take advantage of multi-core computers. The advancement of programming software not only makes it easy to program sophisticated machine tools, but it inherently allows for the production of more efficient machining strategies.

Today’s more sophisticated post-processing and machine simulation have allowed CNC programmers to keep pace with the increasingly complex and growing numbers of mill/turn, Swiss-turn, and 5-axis machines installed around the world.

Due to the latest generation of multicore computers, the improved calculation speed that has resulted from parallel computing algorithms have delivered significant benefits to CNC programmers in the areas of toolpath calculation for complex 3-axis and 5-axis machining, and in machine simulation verification and collision detection.

In terms of significant developments within Esprit, our multi-threaded stock automation engine benefit users who are now able to start the part-program simulation at any time and at any point in the program. This new feature eliminates the need to simulate all operations from the beginning or to save the results of previous simulations. Now Esprit customers can start a simulation with the stock that results from the completion of all previous operations without first waiting for the simulation of the previous operation. The use of multi-threading technology – where stock calculations occur in the background – will not slow the programmer down.

Gibbs: Healthy growth in the MTM machine market is driving demand for capable software. In addition, market acceptance of high efficiency material-removal technology from specialty products, such as VoluMill, as integrated in CAM products, like GibbsCAM, is another growing market.

Fishman: CAD/CAM is an aftermarket product, serving the downstream programming needs of users of machine tools. Thus, if you want to know what the biggest innovation in CAD/CAM has been in the past five years, look at the biggest innovation in machining. Whatever you think the biggest innovation in machining, be it more advanced 5-axis machining, more robust multi-task machining or ever more sophisticated Swiss-type lathes, the biggest innovation in CAD/CAM has been supporting the latest machine tool technology. What is the biggest advancement in machining in the past five years is obviously a highly debatable point.

Sivitter: I think the whole area of simulation, whether machine tool, flow, or kinematics is the biggest advancement.

Freebrey: The biggest advancement in the past five years has been the introduction of software intelligence, reducing the reliance on CAD/CAM experts. Achieved by a knowledge-based database, this adapts over time and is usable by anyone to achieve the same results, following proven and tested rules and conventions. By establishing plant-wide database defaults that represent company standards, this ensures that from user to user, and job to job, you are producing consistent results and high quality tooling.

OptiRough uses the whole flute length for the first cut then adds smaller cuts to get the part to net shape. (Photo: CNC Software)

Adding intelligence to the software enables the system can automatically select the best strategy or machining parameters based on remaining stock or geometrical attributes. One example of this is the ability to take a standard 3-axis toolpath and convert it for use as a 5-axis toolpath, rather than having to rework it from the beginning. This is particularly useful for dealing with both short reach cutters and deep pockets.

The integration of a CAD/CAM system ensures that data can successfully pass from CAD to CAM. Those same features, diameters, hole depths, etc. can all be read, automatically, by the CAM system – providing the user confidence in programming and automation. Once the machining parameters of a feature are known (i.e. the diameter, length, width, depth, type, size, etc.) this feature can be assigned a machining process (i.e. rough with tool 1, re-machine with tool 2, finish with tool 3) to efficiently cut at the machine.

Rusk: At Siemens PLM Software, we have introduced a number of enhancements that have delivered significant value to our customers over the last five years. Most notable is synchronous technology. Synchronous technology allows engineers to make changes to a design without worrying about how the model was originally built, removing the dependency on the recipe (history) that created the model. This approach allows engineers to do more ‘what if’ studies and to investigate more design alternatives in a shorter space of time, allowing them to make smarter decisions on how to solve their engineering problem, and ultimately delivering better products.

The lack of reliance on a feature history also allows engineers easier tools to modify imported non-NX data, allowing companies easier approaches to working with suppliers and partners.

Delcam's FeatureCAM supports machines with C and Y milling capabilities and sub-spindles, letting users manufacture parts that more complex. (Photo: Delcam)

In addition to this, we have seen significant demand to increase the ability to validate design data before physical test. Considerable enhancements to NX simulation solutions (CAE) enable the analysis of complex multi-disciplinary problems for example structural analysis of flexible bodies under motion. This type of analysis can be critical in products combining mechanical, electrical and software elements for example MRI or X-ray scanning machinery.

The increased levels of regulatory controls and higher levels of awareness of customer requirements have created a need to make engineers more aware of the information that supports the development process. At Siemens PLM Software, our investment in our HD-PLM initiatives have focused on bringing the key information to support the design process to an engineer’s desktop without forcing him to leave his CAD session. Tools such as HD3D make the information instantly available to support product development decisions.

Therrien: Many of the major CAM vendors have decided to develop versions of their products that run directly inside CAD software. Currently there are eight CAM vendors that have applications seamlessly integrated within SolidWorks. In other words, the vendors’ CAM software runs directly inside the program so you do not have to import/export data, and anytime you make a change in your design model, the NC toolpaths can update, automatically. The great thing about this is that companies are more than likely using one of the eight associated CAM programs, so no re-training is required. One of our CAM partners, HSMWorks, is even offering a free copy of their fully integrated, 2-½ axis CAM software to all SolidWorks users.
 

TMD: Another response heard during the WESTEC 2008 Roundtable was that there was market saturation of CAD/CAM systems. Do you still see market saturation or is there a change that has happened, a shift?

Picklo: Although there are still shops out there using generic or no CAD/CAM software, the most successful businesses are those that utilize advanced technology to their advantage and software tailored to their business. Many tool shops continued this practice throughout the economic downturn; one of the reasons they likely are flourishing today.

Esprit's seamless CAD to CAM interface directly imports any native part model from any source, fully intact, with no need for programmers to edit or rebuild geometry. (Photo: DP Technology)

Mund: The CAD/CAM market is definitely mature so we have been focusing more on helping shops use their existing equipment (tools and software) to their best advantage.

McMinn: While it is true that it is hard to find a shop without some CAM system, I would question whether there was saturation in 2008. Certainly, the world of manufacturing has changed so much since then that there is no saturation now. Investment in machine tools has recovered dramatically since the downturn. However, the types of equipment purchased today are generally much more sophisticated. That could simply be companies buying machines that operate at much faster speeds, but is more likely to be that the equipment is more complex, such as 5-axis mills or multi-tasking machining centers. This equipment demands more sophisticated CAD/CAM software to perform at its best. However, one consequence of the downturn was that many CAD/CAM suppliers cut their development staff to try to limit their losses as their sales fell. This has meant that they have not been able to keep up with the recent developments in machine tools and cutting tools. Delcam increased their investments in development in preparation for the recovery. The overall result has been a drop in the number of CAD/CAM suppliers that can support the latest machine-tool technology. Of course, many CAD/CAM suppliers can provide basic 2D machining software, so that could be an area considered saturated. In contrast, there is certainly no saturation in the market for high-end programming systems that can maximize a company’s investment in sophisticated machine tools.

Mathews: The CAM market continues to with saturation, though we do predict a small amount of company growth through product improvements, as well as a rise in consumer demand. As there are just a small percentage of companies not utilizing some type of CAM software, those using software that is outdated, unsupportive, or inadequate due to the rapid advancements of more complicated machine tools, such as multi-tasking and Swiss machines often seek us out for assistance. [Therefore], the market must consolidate a smaller number of suppliers and products to provide an economic balance between the expenses required to fund the R&D with the income that is earnable by a given company and product. Upon close inspection, one will find considerable consolidation is actually already underway in the CAM market. For example, DP Technology, among others in the industry, has made significant international strategic acquisitions during the last several years. In selecting a CAM product, the financial position of the supplier helps the consumer understand that if the company and/or product have the strength and commitment to survive the ups and downs of the current economic reality; it is a strong and viable force.

Multi-task machining and machine simulation modules address the programming needs of CNC multi-task machine tools, which employ multiple tool groups/turrets and multiple spindles. (Photo: Gibbs & Associates)

Gibbs: If anything, the maturation of the CAM market continues. The bulk of CAM sales are existing customers growing, and replacement of other systems. There are fewer first time buyers. [However,] there is plenty of opportunity to provide better solutions and service to people dissatisfied with their current CAM product. One sign of a mature market is consolidation and CAM company consolidation continues, as with the Vero purchase of Planit last year.

Fishman: I do not think the competitive landscape has changed much in CAD/CAM since 2008. There are certain areas of CAD/CAM that are saturated, such as the market for software that performs basic functions like 2D milling, 2-axis turning, or basic wire EDM. At the low end, CAM has certainly commoditized, though not totally. That said, on the niche level, including areas such as Swiss turning, 5-axis milling, and other advanced manufacturing applications, there are still very few companies that do this well, so as a result, these niche market sectors are not saturated and therefore have not yet been commoditized.

Sivitter: I would not call it saturation, but clearly, there is a lot of choice and little apparent differentiation in many cases. However, there are differences so there is still opportunity to sell to new customers, and plenty of opportunities with customers who have outgrown their existing system or made a poor choice the first time around.

Freebrey: While many companies already have CAD/CAM systems installed, the need to adapt to changing markets and economic conditions often force a company to change current practices or industry focus. Many CAD/CAM vendors specialize in specific sectors and offer dedicated functionality. The need to remain competitive drives companies to review their currently installed system and, ultimately, switch to another system that better serves their current requirements.

Rusk: It is clear that there are a number of major players in the CAD/CAM marketplace and that number remains steady – there are no new significant players. However, our customers’ market conditions have led to a number of acquisitions and mergers, which has resulted in corporations having multiple systems (as you also found in your 2008 round table). As a result, of the economic climate we are seeing an increase in the number of companies looking to consolidate to single systems to reduce cost, increase communication between divisions, and leverage joint IP. This consolidation is not a simple task, while design data (model data) can be translated between systems, traditionally there is level of information (meta-data, feature history, drawing associativity) that is lost. At Siemens PLM Software, we have been investing heavily on a suite of migration tools that allow companies to protect the investment in their data and then move it to NX as a single system of choice. Development of these tools has been with customer involvement and a focus on bringing a high level of fidelity to the migration process.

PartMaker’s ConfigPost is a powerful and flexible post configuration tool that is also very easy to learn and use. (Photo: Partmaker/Delcam)

Therrien: For sure, there are many solutions to consider, but there is a lot of opportunity when it comes to seamless, integrated, CAD/CAM. The main shift is that users are demanding a tighter integration between CAD and CAM. To be more precise, the purpose of that integration is so they can eliminate the need to translate and repair data, as well as eliminate the need to have to redo their NC programs every time they get a design change.

Additionally, it has become critical to have the ability to pick any best in class CAD and best in class CAM. Users want to be able to select a best-in-class solution for design, and also be able to select a best-in-class solution for CAM. That means that it is possible these products might not come from the same vendor. In the case of SolidWorks, we have been working to fill this need by collaborating with our CAM partners in developing CAM applications that integrate, seamlessly, into SolidWorks – in other words, your choice of CAM directly inside SolidWorks. Currently eight CAM vendors offer fully integrated offerings inside SolidWorks.

TMD: How has concurrent/collaborative engineering impacted CAD/CAM software use and function?

Picklo: Tools that used to take 12 to 16 weeks now require delivery in six to eight weeks. The only way to accomplish this is to have three or four people working on a project at the same time. Concurrent engineering makes this possible – seamlessly.

McMinn: Clearly working directly with CAD files is essential to avoid translation errors. This facilitates direct communication of native files between the different groups. For SolidWorks users, Delcam now has its embedded gold partner product call Delcam for SolidWorks. This product runs inside SolidWorks and the CAM file is actually a part of the SolidWorks assembly file, which is shareable within the native SolidWorks PLM system.

Gibbs: [The impact of concurrent/collaborative engineering is] not a lot in our primary market, the job shops. Our primary customers are not involved in the engineering process. CAM is still the tail end of the process started in engineering. There is an opportunity for CAM technology to provide design input, or design for manufacturability (DFM), and for CAD systems to provide better focused manufacturing data. However, it has not happened yet.

Vero software incorporates specific process knowledge that enables the designer or machinist to achieve complex and precise components in a fraction of the time it takes when using more CAD/CAM systems that are more generic. (Photo: Planit CADCAM Software/Vero Software)

Rusk: Concurrent/collaborative engineering has increased the need for managed visibility of information throughout the process. Closely integrating solutions like Teamcenter with NX has allowed us to deliver a solution that supports shorter development lifecycles by ensuring everybody has access to the right level of data as they need it, managing revisions, release processes and all of the documentation required to support a product as it moves through its lifecycle.

Developments such as the HD3D suite of tools make it easier to communicate key product information across the organization, giving engineers visibility of important information that can impact product development from multiple sources. For example, the ability to visualize, track, and validate a design against the multitude of product requirements throughout the development cycle increases collaboration between organizations and ultimately leads to better products.

The increased use of open data formats such as JT mean that we can make 3D design information available across the enterprise for development reviews and customer and partner involvement. Recently Siemens PLM Software announced the availability of Teamcenter Mobility, delivering a subset of Teamcenter functionality including model visualization on iPad. This makes model data and key product information more accessible across the enterprise wherever the consumer may be.

Therrien: Customers are seeing big advantages (time reduction, improved quality) of integrated CAD/CAM, as long as they are able to select the solution that fits best. For SolidWorks customers, integrated CAD/CAM equates to timesavings between 25% and 90% of their old non-integrated CAD/CAM process.

TMD: What impact has design for manufacturability (DFM) had on the CAD/CAM industry?

Picklo: [With DFM] the tools added enable shops to design faster and shorten delivery times.

Mund: Any improvement of the manufacturability is a huge boom to software and shops. It makes process much quicker in going from art to part. It also helps shops feel more secure that what they are cutting is what the customer intended.

McMinn: Design for manufacturability has become more important as companies have become better at managing the potential conflicts between the optimum design, for either function or appearance, and the cost of producing that design. One trend that has helped is the introduction of direct modeling. The use of this technology in Delcam’s PowerSHAPE and other CAD systems makes it easier and faster to make changes for manufacturing, such as adding draft to walls to make part removal simpler or modifying fillets to make them easier to machine or to speed material flow. Delcam for SolidWorks also provides toolpath generation techniques directly inside of the CAD environment so engineers can analyze, quickly, the manufacturability of design revisions.

Gibbs: Not much [in regards to DFM]; are parts actually being better designed now? I think DFM for CNC is still largely an opportunity not yet realized.

NX8 provides faster programming, automatic tracking of uncut material across multi-stage machining processes, and programming automation for multi-part setups. (Photo: Siemens PLM Software)

Fishman: Believe it or not, the impact design for manufacturability has had in CAD/CAM is still in its infancy. You will see a lot more impact in the years immediately to come. While solid modeling has proliferated heavily in manufacturing, it still has some pitfalls, which is preventing from taking its place as the sole means of conveying engineering data to manufacturers. That said, one recent innovation, direct modeling, which allows for the manipulation of dumb models, i.e. solid models with no design history of feature tree, has been had a huge impact. For example, the recently introduced PartMaker Modeling makes use of direct modeling tools to allow users to modify dumb models such as Parasolid XT, IGES, and/or STEP models. Dumb model formats are very much the preference of OEMs sending work to job shops and contract manufacturers because using such data helps OEMs protect their IP as well allowing them to have the maximum number of potential vendors because it does not require a vendor to have the same CAD system as them to accept their data.

Sivitter: I am not convinced we are there yet. Do designers really think about the manufacturability of the part? Is the software really restricting their design when it knows you cannot manufacture it?

Freebrey: The rapid development of modern 3D CAD systems have facilitated the evolution of product design, and as a result, ever increasing geometry complexity. However, the manufacturability requirements are often an unknown at the time of design. For this reason, CAD/CAM systems need functionality to recognize potential issues at the design stage, before cutting any steel, at the time when the cost of change is minimal.

For example, in the case of a plastic medical part, engineers make key design decisions, such as part thickness, draft angle, thin walls, etc., without knowing the impact on manufacture. In many cases, the moldmaker is responsible for these corrections, but these issues should have been resolved at the design stage.

Rusk: The increasing awareness of approaches such as design for manufacturability has influenced some significant enhancements in CAD/CAM.

First, design for manufacturability has highlighted the need for easy-to-understand design validation tools that allow designers to identify, quickly, problems with designs that may cause problems in the manufacturing process, for example undercuts in cast, forged, or molded parts, and small transitions in machined components. NX Check-Mate is customizable to allow companies to build in their best practice criteria, and comes with 400 out-of-the-box checks usable to ensure designs meet commonly accepted best practices.

Second, closer links between design and manufacture require increased visibility of design intent for the manufacturing engineer. Approaches such as the use of Product & Manufacturing Information (PMI) adding dimensional, tolerance, surface finish type information directly to the 3D model make transferring this information across the enterprise easier. Once again, validation tools to check tolerance information meets company and industry standards allowing a greater degree of confidence when developing new products. PMI can work directly in CAM to automate the creation of toolpath information, adapting speeds and feeds along with material characteristics to improve product quality.

Therrien: The biggest impact is on the cost of manufacturing products. Generally, products that are easier to manufacture will cost less to manufacture. To this end, with our latest release of SolidWorks, SolidWorks 2012, we have included a real-time manufacturing cost estimation tool that works as you design. SolidWorks, through advanced feature recognition, and the application of an easily customizable database of manufacturing processes, parameters, and material costs, checks the design, automatically, figuring out how to manufacture it and displays the unit cost of the product broken down as material and manufacturing costs. This lets designers design for cost of manufacturing earlier in the design phase, thereby hitting cost targets more consistently and eliminating the need to redesign for cost later after release of the product.

SolidWorks Costing compliments our previously released design for manufacturability tool called DFMXpress included with all SolidWorks licenses. DFMXpress checks parts for manufacturing problems that typically designers often overlook, and usually require correction or modified on the shopfloor.

TMD: In regards to the CAD/CAM market, what role is it seen as playing in regards to the increased precision required in manufacturing of today’s products, looking at general manufacturing, as well as manufacturing in industries such as medical device, aerospace, automotive, and energy?

SolidWorks software packages provide a range of capabilities for a comprehensive design solution. (Photo: SolidWorks)

Picklo: As the market demands for precision and micro-manufacturing have increased, CAD/CAM solutions can deliver results of superior surface quality and tight machining tolerance; quick, safe, and high quality machining of miniature parts and molds; shorter machining time and lower tool wear. The things people are doing today, five years ago were not possible. Today with newer machines, higher quality machining customers are able to produce the smallest of parts.

Mund: As demand for precision increases, CAD/CAM software delivers the most potential benefit by offering toolpaths that match the specific precision needs in a variety of industries such as medical, automotive, aerospace, and energy. These industries all need high accuracy, but cut different materials and in different ways. It is vital that CAD/CAM software produce that precision, but takes into account the needs of the specific industry.

McMinn: Precision effectively comprises two related elements: the ability to achieve a particular tolerance in a sensible amount of time and the ability to maintain that tolerance over a run of parts. CAD/CAM is essential for both elements. It allows machine tools to operate to high levels of accuracy and efficiency, and, even more important, makes it possible to maintain consistency from part to part. Producing high precision parts requires a customer to make the most of his machine tool, tooling, and CAM programming. That is why Delcam works so closely with machine tool companies and high precision tooling manufacturers to ensure that our software products work seamless with those of our partners.

Gibbs: I am not sure any of these industries are crying for increased precision, with the possible exception of medical devices. Most industries are crying for higher productivity and reduced labor as a cost factor, so Asian products do not have a significant cost advantage. With the labor costs minimized by high automation (like MTM machines), and the current weak U.S. dollar, U.S. products can compete with anyone on a cost basis, and we have better quality, engineering, etc.

Fishman: There can be no question that manufacturing is getting more competitive. One aspect of this is that tolerances are becoming tighter, decreasing the margin for error to almost none. When squeezing margins in this way, you can only remain competitive through automation. In this regard, CAD/CAM in fields such as medical device, aerospace, automotive, and energy allows the manufacturer to manufacture to tighter, more precise tolerances with a higher degree of repeatability and measurability.

Sivitter: Very little by way of precision; that is the role of the tooling and machine tools – but in terms of design complexity, virtual prototyping, and productivity, it is significant.

Rusk: The CAD/CAM and CAE market is critical to increasing precision at an affordable cost in today’s products. Simply tightening tolerances and increasing inspection alone will not deliver a cost-effective business.

Utilizing CAD data to increase design accuracy combined with CAE tools to validate critical component and assembly criteria will lead to improved designs. The use of technologies such as PMI and 3D tolerancing will allow companies to employ statistical analysis techniques to analyze tolerance stack-up conditions, once again giving engineers the ability to identify and control key contributors to overall product quality.

At Siemens PLM Software, we believe that a closer integration of our CAM tools with the factory floor can help companies improve product quality and get the maximum return from their investment in machine tool hardware. Closely tying our NX CAM solution to the Siemens Sinumeric controllers allows manufacturing engineers to get the most out of their machine tools, increasing control and delivering more efficient toolpath information.

Therrien: One area that we have seen concern is in the passing of tolerance and other manufacturing information from CAD to CAM. Enhanced capabilities in the area of exporting critical manufacturing information, including the joint development of a new product capable of meeting requirements of the new MIL-STD-3100, are hot topics for us. Of course, the increase in the number of CAM vendors that can seamlessly integrate inside SolidWorks will provide direct access to all modeling information such as tolerances, surface finishes, etc. SolidWorks’ goal is to provide the capabilities necessary to allow our customers to meet their design and manufacturing challenges.