Multitasking Revisited: When Hard Machining Jobs Get Easier

The shop discovered that this CAM suite from SolidCAM UK Ltd. (Barnsley, UK) not only supports 2.5D milling and high speed surface milling applications, but also 3D milling and high-speed machining jobs, including multi-sided indexial 4/5-axis milling and simultaneous 5-axis milling, turning, turn-mill and more. Its iMachining technology can save up to 70 percent in machining time and increase tool life dramatically.

The company purchased and fully integrated the SolidCAM software inside the SolidWorks platform to create just one machining program and use the CAD system’s parametric tables to produce the other variants.

“A Ring Fixator instrument we make comes in 12 different sizes and with other CAM systems we would have had to create a separate model for each variation,” explains Dixon. “This CAM software really extends the reach of the CAD system. It enables us to design and manufacture the jigs and produce the CNC program for each of the three operations required to machine each Fixator from one CAD model and one CAM program, compounding time saving on top of time saving. It really impressed our machinists when they realized amount of duplication of effort they had avoided!”

Following an impressive demonstration, Dixon realized their new iMachining module could make a big difference to the ease of machining on the Nexus because it solved the problems of rigidity and efficient metal removal for milling operations on the machine.

“For C-axis milling you often have to compromise on the tooling you select, using longer projections than are ideal,” explains Dixon. “Furthermore, turn-mill machines are typically not as rigid as a machining center. They have less power and the workholding is more flexible, with longer overhang situations than one would like.”

“But,” he smiles, “iMachining produces some incredible results for us on stainless steel. Our machining times are half of what we expected and the cutters last about five times longer than they did previously. We were used to getting unpleasant noises from the machine as it was cutting, but now we just get a sweet milling sound.”

For example, a stainless steel spinal implant instrument manufactured on the Nexus has a turned outside profile with milled sides and a 26 mm deep through pocket in the center, both of which need to be cut using driven tools. The central pocket is cut with an 8 mm long-series carbide tool and finished with a 6 mm tool. iMachining enables this pocket to be cut in one pass at full depth, starting from a pilot hole, without vibration. “With traditional methods we would have had lots of steps down the machined walls,” adds Dixon. “With iMachining we get a lovely smooth and flat finish.”

The shop also found that programming in SolidCAM is easier. The company employs highly skilled engineers, so machinists are able to prepare their own programs while the machines are cutting. “With on-machine programming of complex parts, we would often have the machine tool idle for one or two days while the CNC program was being perfected,” says Dixon. “But iMachining produces code that works the first time and hugely increases our productivity by giving us more machining capacity and virtually eliminating programming and setting time.”

Dixons Surgical feels their future is in producing complex orthopedic instruments with a shop that already has the experience, skill and knowledge required to finish surgical instruments to the required standard. “Our investment in SolidCAM and iMachining is a crucial part of our expansion plans,” states Dixon. “We have been blown away by its performance.”

SolidCAM UK Ltd. BBIC, Innovation Way, Barnsley, South Yorkshire, United Kingdom S75 1JL, +44 (0)1226 241 744, info@solidcamuk.com, www.solidcam.com.