Milling Q&A

CIM asked Hurco Canada’s Sales and Operations Manager Joe Poulin and Application Engineer Ian Candolini about the current state of milling technology

November 1, 2009

Q: How has milling technology changed recently?

A: The inception and dissemination of advanced CAD/CAM packages are giving engineers and designers tools to help them create incredible components. This results in parts with a level of complexity that could not be imagined in previous years which, in turn, results in levels of manufacturing complexity not seen before.

With milling being one of the fastest methods of material removal, manufacturers and consumers of machine tools had to work together to design machinery and processes to maximize efficiency and productivity. This means increasing throughput and decreasing programming and setup time.

Q: Why are these changes important?

A: As more and more work was moved offshore, new methods of manufacturing had to be created to offset the price/productivity gap that exists between North American and Asian manufacturers.

Closing the gap without compromising product quality means applying new material removal techniques and reducing setup time. Hurco also is focusing on providing more five-axis machining solutions with simple, intuitive shop floor programming.

Q: How can manufacturers reduce setup time?

A: Complex setups can make or break a project. If there is one thing a shop foreman or owner can’t control, it’s setup time, as every machinist has different skills and abilities.

Low-yield manufacturing jobs with multiple setups are becoming more and more popular and can require hours of thought and custom fixturing. Taking advantage of equipment with more than three axes is the ticket to profitability here.

Q: How has new tooling led to changes in milling?

A: The new trend is light and fast. The increase in demand and proliferation of high-feed cutters are being matched by smaller and faster machines with metal removal rates comparable to the previous generation of machine tools.

Q: What is the current state of conversational programming in milling?

A: Hurco invented conversational programming; it is part of our roots. We believe in empowering the machinists by giving them the choice on the method of programming, whether it is conversational, NC, or DXF.

We have a vision of how the right application of practical and theoretical programming and manufacturing concepts can be applied to produce incredible results. We are constantly pushing the limits of what people perceive as possible with shop floor programming.

Currently, conversational systems such as Hurco’s Winmax® software allow the creation of nearly any 2.5-D geometry without the aid of CAM software. The creation and machining of true 3-D surfaces on the shop floor already is a reality with the 3-D Mold and Swept Surface modules.

Eventually, conversational systems will become so powerful they may displace the CAM market altogether.

With a decrease of machinist availability or experienced machinists with CNC background, conversational programming gives everyone the ability to operate CNC equipment and allows them to be more productive.

Because of the demand for JIT deliveries and with fewer requests to produce high volumes with stock on shelves, conversational is ideal for one-offs or small batches. An NC-based system can require an experienced CAD/CAM programmer and an experienced operator to get the job done. Conversational systems can be run by just one person, who can be fully trained in days.

When it comes to comparing the two styles of programming, I think they complement each rather than compete.

Q: What will Hurco’s machines of tomorrow look like?

A: Hurco will continue to make faster machines with higher speed capabilities and more multiaxis designs, and our control will continue to evolve with the technology.

How will the machines look? Only the future will tell. New materials and new technologies are revealed every day. Let the machinist of the future tell us.

For more information, visit www.hurco.ca.