Siemens–DMG Collaboration Tightly Integrates Process from CAD to Machined Component

The benefits of tight digital integration, consistency and associativity of data throughout manufacture are particularly important in the aerospace sector, where a mid-size jet contains over four million components and hundreds of design changes are made daily that have implications throughout the global supply chain.

At the DMG Pfronten open house earlier this year, the German machine tool manufacturer announced a new association with electronics giant Siemens that allows additional power to be gained from the NX CAM (computer-aided manufacturing) system from the subsidiary company, Siemens PLM Software, when it is used in conjunction with a Deckel Maho or Gildemeister machine equipped with a Sinumeric 840D CNC.

The tie-up is the first to be implemented to such a comprehensive extent between Siemens and a machine tool manufacturer. Core software from the 840D control of a DMG machine is now supported inside the NX CAM package as a virtual NC kernel (VNCK). It gives NX knowledge as to the best use of the CNC system’s cycles, taking into account DMG machine-specific compatibility features. The built-in post processor can therefore extract all the benefits of advanced functionality within this latest Siemens control, such as advanced surfacing and look-ahead for high speed cutting.

Another advantage of embedding the VNCK in the CAM system is better simulation of axis movements in DMG Virtual Machine software, based on data from post processing rather than using internal tool path data prior to posting. G-code driven, virtual trial cutting more faithfully represents the real axis motions on the customer’s machine. Only then is the program ready to be transferred to the computer numerical control (CNC) running the cutting cycle on the DMG machine. The result is more efficient production of error-free parts in shorter cycle times to higher accuracy and with better surface finish. On-machine probing routines can be incorporated into the programs.

Dirk Rabenek, Siemens’ Head of Competence Centre Aerospace, said that the benefits of tight digital integration, as well as consistency and associativity of data throughout manufacture, are particularly important in the aerospace sector.To make his point, he noted that a mid-size jet contains over four million components and hundreds of design changes are made every day that have implications throughout the global supply chain.

Manufacture starts with creation of a part using Siemens NX CAD (computer-aided design), or importation of a model’s 3D geometry from another CAD system, complete with industry-standard product and manufacturing information (PMI). Data such as GD&T (geometric dimensioning and tolerancing), surface finish, material specifications and textual information can be included within PMI, which is attached to the geometry so that more of the true design intent is captured.

This information drives the manufacturing process, progressing the data through NX CAM, with its extensive feature-based machining capability and knowledge database. There is the option of manual editing to optimize toolpaths, which are laid down using proprietary streamlined techniques resident within the CAM system.

Unification of the CAD/CAM and CNC environments allied to high level process planning and data management are key to achieving enhanced levels of productivity and accuracy. The latest collaboration between Siemens and DMG  allows a machine to be productive immediately it arrives on a customer’s shop floor, even for the manufacture of the most complex, high accuracy parts. Despite its power, NX CAM is accessible to all staff, even on the shop floor. A role-based user environment is created by configuring the software to match the operator’s experience level, the industry being served and the type of machine being programmed.

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