Enabling Multi-Axis Machining and CNC Productivity Optimization with Siemens NX
Customer background
The customer specializes in precision machining of mechanical components for the automotive and motorcycle industries, with diverse manufacturing capabilities including precision CNC machining, casting, welding and other machining processes.
Due to high-volume production and a diverse CNC machine environment, the company has demanding requirements for machining efficiency, product quality, operational safety and the ability to master complex machining technologies.
During production, the customer operates various CNC machines, including advanced machining centers such as Tongtai TD-2000Y and Grob-550. This requires a CAM programming system capable of accurately supporting the kinematics and controller characteristics of each machine.
Key challenges
Optimize CNC machining efficiency
In high-volume production, saving even a few seconds per part can significantly reduce machine time and operating costs while increasing production capacity.
Improve product quality
The company needs to maintain accuracy and process stability to reduce defects, minimize rework and ensure consistent output quality.
Ensure safety and extend tool life
Mill-turn and multi-axis machining involve potential collision risks. Simulation before running the machine helps reduce risks, protect equipment and extend tool life.
Minimize CAD/CAM data conversion errors
Data conversion between design and manufacturing can cause inaccuracies or information loss, disrupting the workflow from CAD to CAM.
Master complex machining technologies
Engineers need to master 2.5- to 5-axis milling, simultaneous 5-axis machining, turning and complex mill-turn operations across different CNC machine configurations and controllers.
Solutions implemented by VBTECH
With years of experience in CAD/CAM consulting, implementation and technology transfer, the VBTECH technical team assessed the customer’s manufacturing processes, analyzed practical requirements and developed a comprehensive solution based on Siemens NX.
1. Integrated CAD/CAM in a single environment
VBTECH implemented an integrated NX CAD/CAM solution, enabling the customer to move seamlessly from design to machining programming within a single environment.
The solution supports a wide range of machining methods, from 2.5-axis to 5-axis milling, turning and complex mill-turn machining, meeting programming requirements for different products and CNC machine types.
2. Dedicated Post Processors for each CNC machine
VBTECH developed and configured Post Processors according to the kinematics and controller characteristics of each machine, ensuring that the generated NC-code is compatible with the actual CNC equipment.
Two representative machine systems included in the implementation are:
| Machine system | Implemented configuration |
|---|---|
| Tongtai TD-2000Y |
|
| Grob-550 |
|
3. Machine Configuration and machining simulation
One of the key project activities was developing a Machine Configuration that accurately represents the actual CNC machine. Through the 3D simulation environment, engineers can verify the complete machining process before sending the program to the machine.
- Verify toolpaths.
- Check collisions between the tool and workpiece.
- Check collisions with fixtures and machine components.
- Verify axis travel limits and machine movements.
- Verify NC-code generated by the Post Processor.
- Optimize machining sequences and cycle time.
As a result, programs can be verified and optimized before actual machining, helping reduce risks and minimize machine prove-out time.
Training and technology transfer
Alongside software implementation and system configuration, VBTECH provided in-depth training and technology transfer for the customer’s engineering team.
The training focused on:
- Multi-axis milling programming.
- Simultaneous 5-axis machining.
- Complex mill-turn programming.
- Toolpath optimization.
- Post Processor operation.
- NC-code simulation and verification.
- Building and reusing tool libraries, fixtures and cutting parameters.
Results achieved
| Master complex machining | The engineering team can independently program complex mill-turn applications and multi-axis / simultaneous 5-axis machining. |
| NC-code compatible with actual machines | Post Processors and Machine Configurations were developed to match each machining center and its actual controller. |
| Improved machining safety | 3D simulation helps identify and resolve potential issues before machining, reducing the risk of collisions and damage to cutting tools, fixtures and CNC machines. |
| Optimized machining time | Toolpaths, machining sequences and cycle times can be evaluated and optimized before actual production. |
| Higher programming efficiency and data reuse | The company can reuse cutting parameters, tool libraries, fixtures, machining processes, programming templates and standardized machining strategies. |
As a result, the company can gradually establish a standardized and consistent machining programming process that can be scaled across multiple product lines and CNC machine types.
Business value
VBTECH’s solution not only addresses programming requirements for individual CNC machines but also aims to establish an integrated CAD/CAM – Post Processor – Machine Simulation environment, helping manufacturers:
Increase productivity → Reduce machining time → Lower costs → Improve quality → Enhance safety → Master complex machining
This provides an important foundation for manufacturers to gradually standardize and digitalize their production processes, strengthen their precision machining capabilities and meet the increasingly demanding requirements of the automotive and motorcycle industries.
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