CAM software considerations

A trial is a good way to dispel any misgivings a user may have about cam software.

Many different computer-aided manufacturing (CAM) software options are available on the market today, and every machine shop and OEM is looking for unique features to optimize its day-to-day operations. Alan Levine, managing director for Open Mind Technologies USA, breaks down for Canadian Metalworking the different options and considerations that manufacturers could explore when purchasing CAM software.

Alan Levine: All CAM software needs a front end for geometry selections or development of reference geometry. The CAM system may be integrated into a commercially available CAD system, or the front end may be a system developed by the CAM provider, often called stand-alone CAM. For example, Open Mind’s hyperMILL® has a fully integrated version available in SolidWorks and in Autodesk Inventor. The benefit of an integrated system is that users are already working in these CAD programs, so they can work in a familiar program and infrastructure. It also means that they don’t have to export and import their data back and forth.

CAM suppliers offer different bundles depending on what the customer is looking for and their machining capabilities. Most of Open Mind’s bundles fall into different functional categories, and users can combine bundles to meet operational needs.

However, we are seeing more and more demand for stand-alone products. Open Mind has developed a CAD-for-CAM program as a front end to our CAM software. This stand- alone product has many functions that CAM users specifically need that are often not found in integrated systems, which are developed primarily for designers, not machinists.

For example, to facilitate some machining processes, it is important to cap holes quickly, whether the top of the hole is planar or curved. Then the roughing procedure does not try to cut into those holes or pockets. Another example of a CAD-for-CAM function is a filter selection to easily select certain face types, such as all cylindrical or coaxial faces, from a complex model. This saves manual selection processes and improves programming efficiency and quality.

These CAD-oriented features are primarily of benefit to a CAM user. In our stand- alone system, we can also import files from SolidWorks, Autodesk Inventor, and other popular CAD systems like Siemens NX and CATIA. The stand-alone product provides a user-friendly environment targeted for the shop floor and manufacturing engineers.

CM: How do you decide between a local CAM environment or a cloudbased system?

Levine: We currently don’t offer a cloud-based option. We have not seen customer demand for cloud-based systems in the CAM sphere. There are some advantages to using cloud-based CAM, but there are also some constraints, particularly for our customers.

For example, many of our customers require the model data and computing system to be local. Some customers take on projects for government agencies that can be highly confidential, and so the data is very sensitive. Many commercial product manufacturers have equally stringent data requirements. For example, an automotive manufacturer would not want data on the cloud because of its multitude of parts.

Alan Levine, managing director for Open Mind Technologies USA.

Another issue with cloud-based CAM is that we have many customers that don’t have internet access on the shop floor, so the cloud will never work for them unless they change their working environment.

CM: What features and applications should users consider when choosing CAM software?

Levine: Like many of our competitors, we offer different bundles depending on what the customer is looking for and their machining capabilities. Most of our bundles fall into different functional categories, and you can combine bundles to meet operational needs. Modules can be added in the future if the user expands its machining capabilities.

We offer a 2D package for plate processing in tool and mould manufacturing, and this is great for users who are working on mould bases and focused on milling pockets and drilling holes. We also have an entry 3-axis bundle, a full 3-axis bundle, and 5-axis packages. We got creative giving users maximum flexibility. Capabilities can be selected in bundles, individually, or include specialty applications such as for tire moulds and turbines.

Sometimes the customer doesn’t know what they want initially as they may be stepping into new machine and part capabilities. The sales process becomes consultative and we can give the customer options to consider and try. Larger module packages cost more, so the customer should consider the right number of features to be able to complete ongoing projects. This is particularly true for customers who are just entering the 5-axis market, need new CAM software, but do not yet have a history with this type of machining.

Some customers like to buy the entire suite and grow into it as needed. The one benefit of these bundles is that you can always turn on a feature as needed. It really depends on the shop and the comfort of the user. For those who choose to be conservative, the software is highly configurable, and required upgrades can be made in minutes.

CM: How important are trials, and what should users be looking for during a trial?

Levine: A trial is a good way to dispel any misgivings a user may have about CAM software. Most people have experienced buying software and they carry those experiences on when looking for new options. Unfortunately, CAM software is not always easy, and sometimes customers may have had bad experiences with it, so they may be nervous or even have false expectations when shopping for a new CAM software. A trial is a way to show users what the CAM software experience will be in day-to-day operations.

Open Mind’s integrated hyperMILL ® MAXX Machining finishing module is the CAM programming source enabling the use of conical barrel cutter technology to reduce cycle times over 90 per cent.

However, sometimes a trial is not always the best way to shop for CAM software. Sometimes we find it’s more successful and instructive for the user if we do a test in their environment on one of their parts. Demonstrating a good machining process that efficiently produces a part with a desired surface finish eliminates a lot of the risk for the purchasing company. When adopting new CAM software, not all users adapt to the changes quickly. A trial doesn’t show off all the functionality, especially for unfamiliar users or those who might expect it to work like other brands, which can be frustrating.

CAM suppliers offer different bundles depending on what the customer is looking for and their machining capabilities.

We like, especially in the more challenging applications, to do things live and unrehearsed, and let people see how the process should work. So sometimes a customer will give us their USB stick for a part they want us to demo. We haven’t seen the part prior to the demo and have not had the opportunity to practice. In this way we can really show them what it’s like to try it out for the first time. Anytime money is invested, there’s a feeling of risk. We want to limit the risk for the prospective buyer and have them feel assured that they will obtain a good return on their investment.

CM: What should a manufacturer consider when choosing where to operate its CAM software?

Levine: Customer environments vary widely, and so do the programming approaches. The differences can be based on production volumes, sizes of parts, machining cycle times, physical distances in a shop, and programmer experiences. Programming can be done on the shop floor by machinists or in an office by tradespeople or engineers. A CAM program should be versatile and well-organized to work in any environment.

Integrated CAD/CAM programs may be better-suited for a CAD department with a full-time programmer. Also, manufacturers who are making small, precision parts very fast would likely benefit from programming before the process goes to the shop floor. On the opposite end, if a shop specializes in larger parts with longer machining times, then shop floor programming tends to make more sense. While the machine is running a long cycle, the machinist can keep an eye on the machine and can prepare the next programming step. The machinist/programmer also takes more ownership of the entire process.

The work flow and programming structure ultimately are the manufacturer’s choice based on the many factors. And choosing the right CAM software product and its options is most effective when the manufacturer works closely with its CAM supplier to determine the right combination of specifications that work for the applications at hand.

All photos courtesy of Open Mind Technologies.

Associate Editor Lindsay Luminoso can be reached at lluminoso@canadianmetalworking.com.

Open Mind Technologies, www.openmind-tech.com

Open minds integrated hypermill maxx machining finishing module is the cam programming