Power of VoluMill

1. Maximizing Output
and Efficiency
A unique perspective on the challenges manufacturers face in the coming decade
and how to overcome them to maximize profitability
Edsel Vaz
Country Manager

2. Confidential

3. Charles Lindberg
On June 11, 1927, Charles Lindberg crossed the Atlantic in his
custom-built plane, “The Spirit of St. Louis”. The craft was stripped
to the bare bones and modified to carry 425 gallons of fuel, enough
for his non-stop journey.
He flew for 34 hours and covered 3610 miles. Thus, he used .11
gallons of fuel per mile! (or 8.49 miles per gallon!)
Confidential

4. Debuting in 1969, the Concorde could take 100 passengers across the Atlantic in 2
hours consuming 6 gallons of fuel per mile or 6407 gallons per hour.
Confidential

5. TECHNOLOGY...
Make it faster…
Confidential

6. The Boeing 747-400 can carry 467 people across the Atlantic in about 6
hours at 646 MPH burning 5 gallons of fuel per mile. The 747 family has
carried half the worlds population 42 billion nautical miles.
Confidential

7. CHANGES…
Make it more reliable and economical…
Balance speed with the lowest cost to meet customer
demand to ensure profitability…
Confidential

8. And now, the Airbus A380 holds the record as the largest airliner in the
world with a capacity to carry 850 passengers half way around the globe
while consuming 10 gallons of fuel per mile. It too can cross the Atlantic
in about 6 hours despite it’s size!
Confidential

9. EVERYTHING…
…We do must meet the changing demands of new Economic
and Market Challenges…
You’ve just seen four approaches to solving the same problem, how the demands
of the market have changed and how one industry has changed to meet theses
demands…
Confidential

10. TECHNOLOGY CHANGES EVERYTHING!
What role will technology play as the demands of your market
increase and your shop evolves to meet the challenges of the future?
Confidential

11. AIRLINE INDUSTRY PROFITABILITY
IS MEASURED BY…
• Equipment uptime
• Passenger seat/mile cost
• Industry compliance
• Reduced costs and overhead
Confidential

12. AND NOW… THE BIGGER PICTURE
• An A380 uses slightly more fuel per passenger, but looking ahead, Airlines
must also meet the added challenges of airport and aerospace
congestion. The infrastructure can only handle so many planes (slots) and
it’s FULL!
• The challenge becomes increasing passenger “through-put” and the A380
carries 850 passengers in a single “slot”, and slots cost money!
• Just like your challenge is increasing part through-put through your
existing CNC machines and shop floor space, which are also limited
• It is the sum of your technology that will overcome that challenge, not just
any one aspect
Confidential

13. IT DOESN’T MATTER WHICH INDUSTRY
YOU’RE IN…
• Survival depends on understanding profit and loss
• Embracing new ideas and technology gives us the competitive edge
• Underestimating our weaknesses can be fatal
• Change is a constant factor, so is the need to improve our processes
and product
• When faced with a challenge, we better see it coming and find a
way to overcome it!
Confidential

14. YOUR PROFITABILITY IS
MEASURED BY…
• Machine uptime
• Material removal rate
• Part compliance
• Reduced costs and overheadMachine Simulation
Plunge Rough
Confidential

15. YOUR PROFITABILITY IS
MEASURED BY…
• Machine uptime
• Material removal rate
• Part compliance
– Machine directly from native CAD models to reduce programming errors
• Reduced costs and overhead
– Increased tool life
– Reduced machine costs
– Increased ROI on machines
– Reduced labor costs
Confidential

16. YOUR PROFITABILITY IS
MEASURED BY…
• Machine uptime
• Material removal rate
• Part compliance
• Reduced costs and overhead
We are going to focus on these two key areas where GibbsCAM
can optimize your productivity and profitability…
Confidential

17. WHAT IS
• It is a performance enhancement for GibbsCAM
• It is a toolpath optimization geared towards maximum material
removal rate
• It’s primary focus is optimized roughing
• It’s objectives are balanced high-volume material removal
rate, optimizing tool life and fully exploiting a machine tool’s
capabilities
Confidential

18. Look at it like bolting a supercharger on a Corvette® Z06!
… only easier, cheaper and with more bang for the buck!
Supercharger
Corvette C6 Z06
Confidential

19. Look at it like bolting a supercharger on a Corvette® Z06!… only
easier, cheaper and with more bang for the buck!
Let’s look at some statistics…
• Stock Z06 • Supercharged Z06
• 505 H.P. • 660 H.P.
• 0-60 – 3.4 seconds • 0-60 – 3.2 seconds
• Quarter mile – 11.57 seconds • Quarter mile – 10.5 seconds
• Upgrade cost $6,000-$10,000
• Installation time: A good day or
so
• % results increase – 7%
• Increase in profitability – 0!
Confidential

20. Now let’s compare this to upgrading your GibbsCAM software
by adding totally integrated VoluMill:
• No tools required
• Installs in seconds
• Totally integrated
• Cycle-time reductions 40-60%
• Upgrade cost (existing GibbsCAM customer): $1,500 - $2,500
• No added skills required
• Increase in profitability – Dramatic!
Confidential

21. MY CAM TOOLPATH SEEMS FINE.
HOW CAN IT BE ANY BETTER?
Let’s discuss some factors that indicate there could be
room for improvement in your roughing processes
Confidential

22. 5 SIGNS THAT YOUR ROUGHING STRATEGY
HAS ROOM FOR IMPROVEMENT:
• Premature tool wear, limited tool life, tool breakage
• Vibration or inconsistent sounds when tool enters cuts, corners,
or changes direction
• The need for increased rigidity in fixturing or part shifting
• Spiral swirling on wall finishes or spiral stepping on floors
• The urge to have a nap while watching your tool cut
Confidential or other remark

23. CONVENTIONAL TOOLPATH CALCULATIONS
a
• Traditionally, area removal toolpaths are calculated by working from a
given shape(s) and calculating offsets inside-out or outside-in
• This has been the industry standard for years and is the approach
commonly applied in most toolpaths of this type by most CAM systems on
the market today
• It gets the job done and does allow for a lot of versatility in tool
application
• It has been a good solution for most applications
Confidential or other remark

24. CHALLENGES PRESENTED
BY OFFSET TOOLPATH
a
Confidential or other remark

25. CHALLENGES PRESENTED
BY OFFSET TOOLPATH
a
• Sharp corners and radical directional changes increase tool loading
• Moving between cuts increases tool loading
• Tool performance is limited by overloading in red areas
• Cut depth, RPM and feed needs to be reduced to survive red areas
• Material removal rate in grey areas becomes limited by red areas
• The result is a compromise in cutting parameters for the entire
operation to ensure cutter survival and a reasonable lifespan
Confidential or other remark

26. DEFINING PRODUCTIVITY
AND EFFICIENCY
• Productivity and efficiency means maximum output with lowest costs…
make more parts in less time, giving you the most profitability!
• Profitability is getting the maximum return from your capital investments
and high-dollar consumables
• Your machine tools and facility that supports them are your largest
capital investments
• Labor costs to support each hour your facility is operational are a
significant overhead
• Perishable cutting tools are one of your greatest consumable expenses
Confidential or other remark

27. YOU INCURE COSTS FOR EVERY HOUR YOU
OWN A MACHINE AND EVERY CUTTING
TOOL YOU BUY… YET:
• CNC machines on average operate at 50% of their true
capacity, and that’s during UPTIME!
• The lifespan of most cutting tools ends prematurely due to
abnormal wear to a small percentage of the effective cutting edge
or damage other than wear from abuse (chipping, pitting, burning)
Confidential or other remark

28. END MILL WEAR CONDITIONS
• Localized depth of cut wear
– Note depth of cut wear
• Catastrophic Shock Wear (vibration, chatter, packing)
• Typical normal wear
Confidential

29. IN A PERFECT MACHINING WORLD:
• Machining would be consistent, uninterrupted and vibration free!
• The entire cutting edge of a tool or insert would be utilized
• Both machine tool and cutting tool technology would be operating
at maximum efficiency
Confidential

30. A SNEAK PEAK INTO THE
PERFECT WORLD OF OPTIMIZED MATERIAL
REMOVAL:
• Video courtesy of Mikael Bagge, Fruktus AB Sweden
Confidential

32. ROI:
REAL WORLD EXAMPLES OF
VOLUMILL PERFORMANCE
Confidential

33. TITANIUM, .500 5-FLUTE:
Before VoluMill After VoluMill
• ADOC: 0.315 (Axial Depth of Cut) • ADOC: 0.600
• RDOC: 0.220 (Radial Depth of • RDOC: 0.035
Cut) • RPM: 3,056
• RPM: 1,225 • IPM: 100
• IPM: 6.25 • Cycle Time: 30:00
• Cycle Time: 80:00 • Parts per Tool: 40
• Parts per Tool: 4 • CIM MRR: 2.10
• CIM MRR: 0.433
(Cubic Inch/P/Minute
Metal Removal Rate)
Confidential

34. WHAT THE CUSTOMER SAID:
“The results were so dramatic that the one order paid for
the software. It’s been all profit after that.”
“Common sense tells me it’s
saving wear and
tear on my machines.”
“It did more than I expected it would do.”
Confidential

35. PERFORMANCE TOOL AND DIE
A2 TOOL STEEL:
Before VoluMill After VoluMill
• 2” insert shell mill & .500 4- • .500 5-flute
flute • ADOC: 1.00
• ADOC: .15 / 1.00 • RDOC: 0.030
• RDOC: 1.25 / 0.02 • RPM: 12,000
• RPM: 700 / 3,000 • IPM: 200
• IPM: 35 / 30 • Cycle Time:
• Cycle Time: 22:36 07:20
Confidential

36. WHAT THE CUSTOMER SAID:
“We realized a 208% increase in productivity.”
“It’s paid for itself in no time.”
“The benefits exceeded our expectations.”
-
Confidential

37. OPTIMA MANUFACTURING
718 INCONEL - .375 4-FLUTE:
Before VoluMill After VoluMill
• ADOC: .125 • ADOC: 5.00
• RDOC: .010 • RDOC: 0.020
• RPM: 1,000 • RPM: 1,000
• IPM: 8 • IPM: 12
• Cycle Time: • Cycle Time:
40:00 17:00
• Part per Tool: 1 • Parts per Tool: 2
• CIM MRR: .01 • CIM MRR: .12
Confidential

38. WHAT THE CUSTOMER SAID:
“The new toolpath removes the material much faster while putting far
less stress on our cutters and machines.”
“Not only is the cycle time dramatically shorter,
but the extended tool life is impressive.”
“Management was easily convinced with such a quick
ROI.”
- Jonathan Wang, Optima Manufacturing
Confidential

39. Typical Toolpaths
• Created by offsetting boundary geometry
• Tools encounter excess material:
• With the initial cut
• When connecting from one cut to the next
• When feeding past the turning point of the previous cut
• When feeding into new areas
• Increased MRRs, increased loads

40. Following Offsets

41. Initial Cut

42. Initial Cut

43. Initial Cut

44. Between Cuts

45. Between Cuts

46. As Desired

47. Increasing Load

48. Into Corners

49. Cut Width
• Makes it easy to generate toolpaths
• Establishes poor machining conditions
• Requires machine tools and cutting tools to
operate under unreasonable circumstances
• Causes load fluctuations
• Causes variations in MRRs

50. The Result?
• Machine tools and cutting tools are either abused
or under utilized – they never get to run in their
sweet zones
• Toolpaths are the weak link in the milling chain of
events
• Milling productivity is far below its current
potential

51. Tail Wags Dog
• Sharp corners increase tool load
• Moving between cuts increases tool load
• Tools abused in red areas
• Parameters must be set to survive red areas
• Tools under utilized in gray areas
• Parameters inefficient for majority of path

52. The Solution?
• Better toolpaths; toolpaths that:
• Enable machine tools and cutting tools to run to
their full potential
• Toolpaths that are not the weak link in the milling
chain of events
• Make the Cut Width parameter a cause-and-
effect parameter

53. ™
V OLU M ILL
• Patent-pending toolpath technology
• From the words volume and milling: manages the
rate of material removal for even machining loads
• Uses the Cut Width parameter to control the width
of cut on the machine
• Enables machine tools and cutting tools to operate
under ideal conditions

54. Ideal Conditions

55. Aerospace Job Shop
625 Inconel, .500 5-Flute
• Before VoluMill • With VoluMill
– 0.250 ADOC – 0.600 ADOC
– 0.400 RDOC – 0.070 RDOC
– 400 RPM – 3,000 RPM
– 2 IPM – 30 IPM
– 00:35:00 Cycle Time – 00:07:00 Cycle Time
– 3 Parts per Tool – 12 Parts per Tool
– Tool cost = $15/Part – Tool Cost = $3.75/Part

56. Motivation
“Manufacturers want to increase
productivity, but without capital expenses or
labor increases.”

57. Capacity
• Manufacturers have plenty of untapped
productivity capacity
– Your machine tools are capable of significantly
higher productivity levels at reduced costs
– Your cutting tools can remove material much
faster, last much longer, and be used completely
• But traditional toolpaths render this capacity
potential unreachable

58. Why VoluMill
• Adding better toolpaths to your operation:
• Is inexpensive
• Is simple – be up and running in minutes
• Is unobtrusive – runs inside GibbsCAM
• Has an immediate impact – quick ROI

59. Questions?

60. HOW ARE CUSTOMERS USING GIBBSCAM WITH
VOLUMILL ACHIEVING THESE RESULTS
a
• They experienced an instant gain of 30-60% in productivity
• They benefited from an increase of tool-life of 50% or much more
• They saw an immediate return on investment
Confidential

61. IF A TOOLPATH CONTAINS BOTTLENECKS, IT’S ONLY
AS FAST AS IT’S WEAKEST LINKS…
a
Confidential

62. IT SOUNDS LIKE MAGIC, BUT IT’S REALLY QUITE
SIMPLE…
a
• VoluMill creates a more uniform toolpath that allows a
cutting tool to maintain optimal cutting conditions on it’s
depth of cut and radial in-feeds
Confidential

63. SAME CNC MACHINES,
SAME CAM SOFTWARE…
a
• No new skills or retraining required
• Same postprocessors, no post editing
• Savings begin on the first job programmed!
Confidential

64. LET’S HAVE A CLOSER LOOK
AT FOR
a
Confidential

65. IT’S QUICK, EASY, AND PAINLESS!
• Supports Mill, Mill/Turn, and Multi-Tasking-Machines
(MTM)
• Totally integrated with GibbsCAM Machine Simulation to
further reduce machine downtime and increase
profitability
• No special post processors or post editing required
Confidential

66. THE END…
Of the presentation…
THE BEGINNING…
Of a new outlook on more efficient material removal…
You have seen what VoluMill CAN do,
and you’ve seen what it HAS done for other companies,
so start saving today and try it at your shop for FREE
for 30 days!
Confidential

68. Thank you for your time.
We know it is VALUABLE!