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Automotive and transportation Grieshaber Using NX Virtual Machine Tool enables automotive parts manufacturer to reduce setupwww.siemens.com/nx " id="pdf-obj-0-2" src="pdf-obj-0-2.jpg">

Automotive and transportation

Grieshaber

Using NX Virtual Machine Tool enables automotive parts manufacturer to reduce setup time by 20 percent

Product

NX Virtual Machine Tool 840D

Business challenges

Make more efficient use of single- and multi-spindle machines

Shorten setup time of machines Reduce product unit costs

Keys to success

Operate INDEX turning machines with Siemens’ SINUMERIK 840D controls

Use Virtual Machine Tool to program machining processes and optimize CNC programs

Use CNC simulation software to synchronize machining and reduce cycle times

Results

Reduced setup time by 20 percent for new and complex parts

Reduced cycle time and idle time of INDEX machines

Accurately calculated expected unit costs during the ordering stage

Improved training of setter and machine operator on the

Virtual Machine Tool

Grieshaber Group fully leverages INDEX machines by implementing Siemens PLM Software solution

Optimizing CNC code

More aluminum rods are machined in the small German town of Schiltach at the Grieshaber GmbH & Co. KG (Grieshaber) plant than at any other location in in Germany. Grieshaber annually processes up to 3,500 tons of aluminum into high- precision parts for the automotive indus - try, many of which are safety-critical

components. “We supply many first-tier suppliers with hard-to-manufacture parts,” says Günter Weißer, the production manager at Grieshaber.

Machining aluminum into high-quality parts is one of the Grieshaber’s core com- petencies; in the latest supplier survey, Grieshaber achieved an impressive reject rate of just 0.8 parts per million (PPM). The company also manufactures high-precision stainless steel parts used in special applica - tions in measuring and sensor equipment, machine and apparatus engineering, and medical equipment. Grieshaber’s biggest

Automotive and transportation Grieshaber Using NX Virtual Machine Tool enables automotive parts manufacturer to reduce setupwww.siemens.com/nx " id="pdf-obj-0-50" src="pdf-obj-0-50.jpg">

A look inside a multi-spindle turning machine illustrates just how complex the synchronization of the moving paths is. Illustration: Wendenburg.

“We used to have to play around with the CNC code and weren’t able to import the adjustments that we made back into the CAM program. Now I can prepare the programs using the Virtual Machine Tool, send it to the real machine, check the quality and then import it back into the Virtual Machine Tool to further opti- mize the CNC code.”

Thomas Dieterle

Technical Planning

Grieshaber

The mobile workstation allows adjustments to the multi-spindle machining process in advance on the virtual machine. Illustration:

Wendenburg.

“We used to have to play around with the CNC code and weren’t able to import

The fleet of machines includes over a dozen multi-spindle machines from INDEX, which are all equipped with SINUMERIK 840D control. Illustration: Wendenburg.

customer for high-precision stainless steel parts is its affiliate VEGA, which manufac - tures measuring and level sensor equip- ment, and exports this equipment across the globe.

Although the machining of stainless steel parts is predominantly carried out on sin- gle-spindle machines due to the lower piece count, the aluminum parts are usually machined on multi-spindle turning centers. Grieshaber relies on products from INDEX and product lifecycle manage- ment (PLM) specialist Siemens PLM Software for a winning combination. The fleet of machines encompasses nearly 20 six-spindle machines, including INDEX MS 22, MS 32, MS 40, MS 50 and MS 52 in a

variety of configurations. They are equipped with Siemens’ SINUMERIK 840D controls. Grieshaber’s most recent acquisi- tion is the INDEX MS 22-8, which has eight spindles and can cut parts with higher complexity, or parts with less complexity at a faster rate.

In the past, a 2D computer-aided manufac - turing (CAM) system that only offered minimal options to monitor and detect collisions was routinely used to program single- and multi-spindle machines. The operators would only see what they programmed once the computer numeri- cal control (CNC) program was executed.

Unlike ordinary CAM programs, the Virtual Machine Tool doesn’t just enable the user to visualize the machining process and tool- paths, it simulates the machine movements based on the generated CNC code.

“We used to have to play around with the CNC code and weren’t able to import the adjustments that we made back into the CAM program,” says Thomas Dieterle, Technical Planning, Grieshaber. “Now I can prepare the program using the Virtual Machine Tool, send it to the real machine, check the quality and then import it back

into the Virtual Machine Tool to further

optimize the CNC code.”

Cutting cycle times

The Virtual Machine Tool 840D in the NX™

software suite of solutions from Siemens PLM Software is a CNC programming and simulation environment that allows the user to program the machining operations on a standard personal computer (PC), just as the user would on the real machine. The difference is that using the Virtual Machine Tool, an operator or setter can see if the machine will do what the operator thought it would do in a simulation on the com- puter. Unlike ordinary CAM programs, the Virtual Machine Tool doesn’t just enable the user to visualize the machining

process and toolpaths, it simulates the machine movements based on the gener- ated CNC code. Virtual Machine Tool solutions are configured by machine tool original equipment manufacturers (OEMs), such as INDEX, using a flexible software kit available from Siemens PLM Software. The

“We used to have to play around with the CNC code and weren’t able to import

The distribution of operations of the virtual machine are discussed. Illustration: Wendenburg.

Virtual Machine Tool is built on real SINUMERIK controller software (not a software emulator like most machine tool simulations) and the human machine interface (HMI), combined with full- function machine simulation system, and is calibrated using configuration data from the SINUMERIK controller on the real machine tool. This provides the most com- plete simulation, and means that using the Virtual Machine Tool is just like working on the real machine.

“ I can see if a certain position is too long as early as in the planning stages. So I can achieve my planned cycle times on the real machine much faster.”

Thomas Dieterle

Technical Planning

Grieshaber

...

the

user can see how long the tools are

in operation on each spindle, and make

any necessary changes to distribute the operations more evenly.”

Hubert Firner

Technical Planning

Grieshaber

“ ... the user can see how long the tools are in operation on each spindle,
“ ... the user can see how long the tools are in operation on each spindle,

The Virtual Machine Tool allows a user to virtually simulate and optimize mechanization on the INDEX machines, shortening idle times for

changeover. Illustration: Grieshaber.

“The machining operations are not only displayed from a kinematic standpoint to detect any possible collisions, but they’re also simulated according to their proper temporal sequence and duration,” says Hubert Firner, Technical Planning, Grieshaber. “With the help of a simple image, the user can see how long the tools are in operation on each spindle, and make any necessary changes to distribute the operations more evenly.”

“I can see if a certain position is too long as early as in the planning stages,” says Dieterle. “So I can achieve my planned cycle times on the real machine much faster.”

To optimize cycle times and reduce the time that INDEX machines stand idle (for example, by shortening a feed path and thereby cutting off a tenth of a second from the cycle time), the Virtual Machine Tool provides the same ability to record cycle times that is also available on the real machine. A tenth of a second can quickly add up to a savings of several days per year when dealing with hundreds of millions of parts. That’s why such optimiza - tions were also performed in the past, albeit irregularly, since it always required a stoppage of the machines. It only made sense for parts that were machined in large quantities.

Solutions/Services

NX Virtual Machine Tool

Customer’s primary business

Grieshaber machines and produces over 120 million precision parts from non- ferrous metals annually, primarily for the automotive industry. It is part of a corpo- rate group that also includes VEGA, which manufactures level and pressure measure - ment equipment, and Subfina, which produces surface finishing systems. www.grieshaber-praezision. com/index-eng.html

Solutions/Services NX Virtual Machine Tool <a href=840D www.siemens.com/plm/ nxcam/virtualmachinetool Customer’s primary business Grieshaber machines and produces over 120 million precision parts from non- ferrous metals annually, primarily for the automotive industry. It is part of a corpo- rate group that also includes VEGA, which manufactures level and pressure measure - ment equipment, and Subfina, which produces surface finishing systems. www.grieshaber-praezision. com/index-eng.html These stainless-steel pressure connectors used in measuring and sensor equipment were machined with the multi-spindle INDEX MS 40. Illustration: Grieshaber. “ The changeover time for preparing new parts has decreased by approximately 20 percent.” Customer location Schiltach Germany “Thanks to its easy-to-use design, the Virtual Machine Tool is already very useful in the ordering stage, since it lets you calculate opera - tion times reliably which, in turn, allows you to provide a very precise quote to the customer.” Hubert Firner Technical Planning Grieshaber Günter Weißer Production Manager Grieshaber Reducing setup time by 20 percent The effect of the Virtual Machine Tool on machine operating times is not yet fully known. However, as Weißer says, “The changeover time for preparing new parts has decreased by approximately 20 percent.” “The time saved depends on the complex - ity of the part and on any additional equip- ment that has to be mounted,” says Firner. “Thanks to its easy-to-use design, the Virtual Machine Tool is already very useful in the ordering stage, since it lets you cal- culate operation times reliably which, in turn, allows you to provide a very precise quote to the customer.” The savings potential of running a CNC program is amplified, since it’s also a ques - tion of how much a machine setter can trust the program. Even more important is that the Virtual Machine Tool is an open network solution with multiple user licenses. The machine setter has a station- ary and mobile workstation, so the setter can view the processing of a new part on the computer, but also optimize an exist- ing CNC program even further. That makes the Virtual Machine Tool the setter’s tool as well. The machine setter and machine operator receive training on the Virtual Machine Tool without having to shut down the real machines. As a result, Grieshaber can train and familiarize more employees with both the machines and their controls. Siemens Industry Software Americas +1 314 264 8499 Europe +44 (0) 1276 413200 Asia-Pacific +852 2230 3308 www.siemens.com/plm © 2013 Siemens Product Lifecycle Management Software Inc. Siemens, the Siemens logo and SINUMRIK are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter and Tecnomatix are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. Z11 37457 11/13 A " id="pdf-obj-4-17" src="pdf-obj-4-17.jpg">

These stainless-steel pressure connectors used in measuring and sensor equipment were

machined with the multi-spindle INDEX MS 40. Illustration: Grieshaber.

“ The changeover time for preparing new parts has decreased by approximately 20 percent.”

Customer location

Schiltach

Germany

“Thanks to its easy-to-use design, the Virtual Machine Tool is already very useful in the ordering stage, since it lets you calculate opera - tion times reliably which, in turn, allows you to provide a very precise quote to the customer.”

Hubert Firner

Technical Planning

Grieshaber

Günter Weißer

Production Manager

Grieshaber

Reducing setup time by 20 percent

The effect of the Virtual Machine Tool on

machine operating times is not yet fully known. However, as Weißer says, “The changeover time for preparing new parts has decreased by approximately 20 percent.”

“The time saved depends on the complex - ity of the part and on any additional equip- ment that has to be mounted,” says Firner. “Thanks to its easy-to-use design, the Virtual Machine Tool is already very useful in the ordering stage, since it lets you cal- culate operation times reliably which, in turn, allows you to provide a very precise quote to the customer.”

The savings potential of running a CNC program is amplified, since it’s also a ques - tion of how much a machine setter can trust the program. Even more important is that the Virtual Machine Tool is an open network solution with multiple user licenses. The machine setter has a station- ary and mobile workstation, so the setter can view the processing of a new part on the computer, but also optimize an exist- ing CNC program even further. That makes the Virtual Machine Tool the setter’s tool as well. The machine setter and machine operator receive training on the Virtual Machine Tool without having to shut down the real machines. As a result, Grieshaber can train and familiarize more employees with both the machines and their controls.

Siemens Industry Software

Americas

+1 314 264 8499

Europe

+44 (0) 1276 413200

Asia-Pacific

+852 2230 3308

© 2013 Siemens Product Lifecycle Management Software Inc. Siemens, the Siemens logo and SINUMRIK are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter and Tecnomatix are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. Z11 37457 11/13 A