NC-Programming / Computer Aided Manufacturing
Starting from the CAD model, we develop complete manufacturing processes providing the finished prototype to our customers. We lay emphasis on 3D CAD modelling and on NC-programming of 5-axis milling machines. On customer request, we design the CAD model, optimize the CAD model for manufacturing purposes, generate NC-programs, simulate the milling process on the computer and do the machining of the prototype part in our precision machine shop. During the milling process in our workshop or on the customer machine, it is possible to further optimize the NC-programs in terms of milling speed, process stability, or tool wear. The feedback that we get from the machining in our workshop is essential for the improvement of our programming strategies and keeps us on the edge of machining technology.
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Milling an impeller from the shroud ring:
Collision check of the machine spindle with the part by simulation on the computer. |
Impeller-Manufacturing
The Engineering and Service Department of Sulzer Innotec has a long-standing experience in the production of impellers. This experience covers pumps, compressors, water turbines, as well as blisks. We work with various materials and impeller sizes ranging from small impellers of ø25mm up to large impellers of more than ø1200mm. We generate 5-axis NC-programs for impeller blades with ruled surfaces, arbitrary surfaces, or for integrally milled shrouded impellers.
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Milling a large impeller, stainless steel
(ø 1280 mm) |
Integrally milled impeller, aluminium
(ø 322 mm)
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Numeric Postprocessors
Postprocessors are software tools that translate general NC-code from the NC programming software into a machine specific G-Code language. Engineering and Service develops postprocessors e.g. for the 5-axis milling of impellers or within customer projects. Since the APT/CLDATA code, a common output format of NC-software, is standardized, it is the preferred input code for developing our postprocessors. Other NC-formats must be sufficiently documented to be processed. Furthermore, in the development of postprocessors the following issues should be taken into account:
In the area of simultaneous multi-axis milling, it is possible to calculate the dynamic axis drive within the postprocessor or to have the machine controls calculate it. Programming machine cycles should be done according to the individual requirements of the machine operator.
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Huron KX-100 |
Reverse Engineering
In Reverse Engineering we focus on the reconstruction of the original design entities of machine components. By modeling these design entities in the 3D CAD software, we are able to optimize the manufacturing process for the reproduction of the part. With respect to manufacturing by milling, it is possible to mill planar faces in two axis mode, and to machine ruled surfaces by flank milling. In contrast to primitive models based on triangulated surfaces, our reverse engineering approach also allows the multifunctional use of the CAD model in various engineering software.
For digitizing unknown part geometries we use an automatic, tactile scanning device.
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Automatic, tactile scanning device |
Manufacturing Projects
We assume project management assignments with considerable value creation in the fields of machining, welding, brazing, or material testing. We assure you a professional project management and high engineering skills. Our qualitiy management is certified according to ISO 9001 and ISO 9100 and our manufacturing department is HP 0 certified according to DIN EN 729 – 2. Due to our flexibility we are most efficient even in the area of single part and small series production.
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Copper conductors (1200 mm long) | |