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Oct 14, 2024

Mastering complex precision machined parts - Aerospace Manufacturing and Design

Edited by Eric Brothers, Editor - Manufacturing Group Until five years ago, JR Machine could have been considered a general job shop for lathe work. It was a well-known, well-respected name in the

Edited by Eric Brothers, Editor - Manufacturing Group

Until five years ago, JR Machine could have been considered a general job shop for lathe work. It was a well-known, well-respected name in the Shawano, Wisconsin, area for custom manufacturing, but it was destined for greater things.

Now, though still primarily focused on turning, JR Machine is a leading contract manufacturing company for complex precision machined parts. It’s focused on emerging technologies, especially in the aerospace, defense, and energy sectors, and it’s becoming a go-to manufacturer for machining superalloys. JR Machine’s customers trust the company to produce the best possible parts in its ISO 9001:2015-, AS9100D-, and ITAR-certified shop. These certifications are integral to the company’s culture, which centers around quality, anticipating problems, automation, and process efficiency.

JR Machine’s state-of-the-art shop is home to more than 50 pieces of powerful technology, mainly DMG MORI NLX series turning centers. The 25 DMG lathes can turn parts from 1" to 18" in diameter. All machining units, including horizontal and vertical machining centers, quality assurance aids, and support equipment, are organized in a cellular manufacturing design to increase throughput. Many of the machining centers, still new to the shop, are a testament to its growth. Also key to the company’s growth is a newly expanded quality lab/cleanroom to inspect 100% of the parts flowing through the facility.

The biggest upgrade at JR Machine, however, has been to its software.

Before JR Machine first started contracting aerospace parts in 2020, the blueprints customers sent had been detailed and comprehensive. However, the aerospace parts were directed by minimal dimension drawings with general tolerances, paired with CAD models. JR Machine needed sophisticated CNC programming software that could interpret the customer’s solid model and then apply efficient cutting strategies to it. They chose Mastercam CAD/CAM software from CNC Software LLC in Tolland, Connecticut.

“We’ve tried to target the aerospace industry, which requires highly complex parts,” says Shane Kunschke, JR Machine VP of Manufacturing. “That’s what drove us to purchase new CAD/CAM software. We haven’t made any CNC machine upgrades, but our machines are now capable of doing this high-end work.”

The CAD portion of the software renders the customer’s vector-based drawing to create an accurate and precise model of the part, complete with tolerances and surface finishes. Because JR Machine uses an integrated system, pulling the CAD file into its CAM interface takes no time and means no loss of data. Now, the company can work with whatever prints and models it receives.

“We have to be prepared to receive a blueprint with minimal dimensions yet still be able to machine the part. And that’s where the software has really helped,” Kunschke says.

In the case of complex aerospace parts, JR Machine was writing a workable CAM code but had to return to it often to hand-edit the G-code. Lead Programmer Brock Jaskolski shared that he found writing a mill program easiest, but he had to tweak it to work with lathes, essentially doubling his programming time and increasing operator error. Jaskolski knew his software could do better, so he reached out to his certified local Mastercam reseller, ShopWare Inc. in Elgin, Illinois.

ShopWare Application Expert Todd Rathkamp was quick to suggest the software’s Mill-Turn solution, which harnesses the powers of milling’s tool rotation and turning’s workpiece rotation. Parts previously turned on a lathe, then milled can now be cut entirely on one CNC machining center with Mill-Turn. Productivity is greatly increased because multitasking CNC machines reduce multiple setups, manual part handling, redundant fixturing, and machine downtime.

ShopWare hosted the Mill-Turn training for JR Machine’s team and is still available every day for troubleshooting. Now Jaskolski uses Mill-Turn for plug-and-play-style machining. Kunschke estimates the change will increase machining efficiency 100%.

Jaskolski relies heavily on the Mill-Turn product’s included simulation package. In addition to verification functions, the integrated simulation offers a digital twin of whichever machining unit is paired with a particular part. Jaskolski can load his program and watch it run in real-time on a detailed virtual representation of his CNC units. Ambiguity surrounding kinematics is eliminated; the digital twin moves exactly the same as its real-world counterpart. This is crucial for JR Machine, which often deals with difficult materials and produces parts with extremely precise quality parameters. Jaskolski uses his simulation to check clearances and the overall functionality of his machine, especially when working with something relatively new to him, such as 3D milling the edge to a part with a radius.

“The simulation we have now is 10 times better than what we had before,” he says. “Everything is smoother, and we can get an accurate gauge of how parts will run on our CNC machines. We don’t have to make many alterations to the program before it goes to the machine. It’s almost a plug-and-play system.”

JR Machine is still a lathe-focused operation; 3D milling is somewhat novel. However, the parts the company takes on are becoming more complex. To meet this head-on, Jaskolski uses CAD/CAM software to simulate 3+2 simultaneous machining, harnessing the power of multi-axis machining within a 3-axis environment by tilting the tool held at a fixed angle. Using a successive sequence of orientations, users can mimic 5-axis simultaneous machining without going all-in on multi-axis. Jaskolski mainly uses the technique to machine the radius on Inconel parts. Recently, he applied it to flanges for a fuel line component. The flanges vary between 4" and 18" in diameter and between 4" and 8" long, but they require tolerances of about ±0.0005". Their thin walls are a particularly tricky piece of geometry.

To ensure successful programming, Jaskolski’s team called upon one of its best resources, ShopWare, whose experts helped program the part with JR’s team and stuck around to make sure the actual toolpaths matched the simulation. This software includes specifications for all the machines in JR’s stable, enabling one-touch uploading of each machine’s capabilities into the system. From there, toolpaths are created quickly and easily from a solid model using Mill-Turn.

Jaskolski still calls on ShopWare when he needs support. JR Machine keeps its software subscription current, so updates come automatically and technical support is always available. The reseller makes sure JR Machine is taking full advantage of the software’s capabilities. One suggestion from the reseller was Dynamic Turning, powered by Dynamic Motion technology. Dynamic toolpaths are stock-aware and intelligent. During machining, a Dynamic Turning toolpath will adjust rotation speed, cutting angle, and tool depth to perfectly match the machining environment. Chip size is optimized, materials and tools are safeguarded, and the machine will be free to run faster than before.

“The Dynamic options allow the tool to sweep through the part much more smoothly, with less wear on the insert,” Jaskolski says. As a result, the code is essentially foolproof; all an operator needs to do is set the tools and workholding, then walk away.

Not only does the CAD/CAM help JR Machine maximize its milling and turning operations, it’s also advantageous in employee training.

“Using Mastercam has really helped with training,” Kunschke says. “Now, it’s much easier to get people up to speed. It’s hard to find experienced employees, so if Brock can program a part in the office and make it almost foolproof as it goes to the machine, it’s easier for an operator to comprehend what’s going on. The operator no longer has to massage the program or know exactly what every single line of code is doing.”

Kunschke adds that JR Machine’s CAD/CAM suite hasn’t pushed the company in any specific direction, but it has opened doors. The aerospace, energy, and defense sectors demand the best part traceability, quality, and delivery times. Now the company is free to pursue deals in the latest and greatest emerging markets.

“We’re always going after new business – we’re constantly growing. CAD/CAM software has definitely opened our eyes to the different parts we can manufacture with it,” he says.

JR Machine Inc.

Mastercam (CNC Software LLC)

ShopWare Inc.

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