GE Fanuc and Renishaw bring you the latest probing technologies to deliver more good parts out the door at the lowest cost.

Workpiece Setup

Many machining center parts require complex, time consuming setups to establish the part reference point prior to machining.  Accordingly, the typical VMC only achieves around 30% utilization. 

A spindle probe can locate the workpiece and measure the orientation of key features in a fraction of the time it would take using traditional dial-indicator techniques. Depending on the complexity of the part blank, the CNC can apply tools from simple work offset values to 3D coordinate rotation to adjust the part program to the actual part orientation automatically.

One manufacturing plant saved over $3,000 in labor costs and 30 hours of machine production time on a single job of 48 parts using a Renishaw spindle probe.

Using Dial Indicators

Indicate 4 holes/part:         40 minutes
Lot size of 48 parts:           32 hours

Using Probe

Probe 4 holes/part:            2 minutes
Lot size of 48 parts:          1.6 hours

Savings

30 hours @ $100/hr:          $3,000

Fixture Costs

Traditionally, designing custom fixtures has solved complex part holding and datum reference problems. Custom fixtures are expensive to design and manufacture, and inventory and storage costs are high.  Part modifications may require a fixture to be modified or even replaced.  Fixture lead-time also limits the lead-time of the initial batch of parts ordered.

By using simple part holding techniques such as clamping, and using a spindle probe and CNC compensations to adjust for part orientation, complex fixture costs can be eliminated.  By eliminating specialized fixtures, a business can gain a competitive advantage, particularly on the delivery time of the initial parts order.

Difficult Setups

Some parts are difficult to setup, even with custom fixtures.  Heavy parts can be difficult to orient precisely.  Complex castings and welded fabrications may not have external surfaces that can be used as a reliable reference. Many parts must be rotated or reoriented in the middle of the part program to complete machining of all surfaces.

Simple clamps and fixtures can be used to secure the workpiece at any orientation and probing can be used to compensate the part program accordingly. The increased flexibility achieved may allow a business to accept more complex machining work than previously possible.

High-Value Parts

The aerospace, turbine blade, die mold and other industries often process parts with a high initial value. Sometimes the special materials or casting being machined are expensive. Sometimes it is the investment in prior processes that must be protected.

In these environments, probing can be used to validate every aspect of the process including tooling, fixture identification, part blank verification and critical feature dimensions.

Probing can optimize machining within the envelope of the blank or casting.  Conservative machining practices can be adopted and the depth of the final cuts can be optimized after a strategic probe measurement near the end of the cycle.

Error-Proofing

Traditional tool geometry and tool wear offset management requires perfect operator execution.  Random offset table locations are assigned to specific tool length or radius attributes. The operator must calculate the combination of the tool geometry and the tool wear values and then edit the correct table value.  Decimal point and digit order data entry errors are common.

Establishing a tool offset data set for each tool with individual entries for geometry and wear values for both the length and radius characteristics simplifies tool offset management. Probing automates both the measurement and data entry tasks associated with tool geometry and wear offsets, error proofing the process.  Further error-proofing is possible with broken tool detection, and with part load and fixture validation.

Tool Setup

As manufacturing lot sizes continue to shrink and labor content limits cost reduction opportunities, it becomes more difficult to use external setup techniques for setup time reduction.

Tool Setting probes eliminate the cost of external setups and specialized qualified tooling.  Geometry offsets are automatically set for new tools and inserts.

The non-contact tool setter delivers rapid tool geometry measurements and provides high-speed tool breakage detection, whereas the economic mechanical tool setter can be mounted outside of the normal machining envelope. Tool probing maximizes flexibility while minimizing tool setup time.

In-process Metrology

Years of experience in Renishaw's own world class manufacturing facilities have validated the benefits of in-process metrology.  Today’s machines and CNC technologies can exceed the accuracies of traditional CMMs.

Critical part dimensions can be measured without removal from the machine.  Any corrective actions can be applied without additional setup and rework. 

Traditional gauge validation and SPC techniques are applied to the machine tool rather than the CMM. Improving the process capability of the machine tool eliminates scrap and work-in-process inventory, removes post-process bottlenecks, and ultimately reduces lead-time and cost.

Problem Solver

Setup automation simplifies ISO-900x and QS-900x certification.  Measurements can be automatically archived for traceability requirements, and the data can be mined at any time for continuous improvement programs.

Probing is a solution for situations with complex setups and a low-skilled workforce.  Automation can free the operator to manage multiple machines or to perform external setups.

In this era of increased competition and shrinking piece part prices, Job Shops must implement technologies for cost and lead-time reduction to remain competitive and profitable.

Turnkey Solution

Until recently, adopting probing required the coordination of several vendors to implement the solution.  Complete turnkey probing solutions are now available for the first time from the industry experts.  The combination of Renishaw’s probing technology and GE Fanuc’s CNC and Six Sigma expertise delivers immediate results.

Packaged solutions include all the necessary hardware and software components, supported by world class installation and training.  Qualified engineers will install all required CNC upgrades and probe components and ensure that the total system is working to specification. Onsite training will ensure that the investment benefits are realized immediately.

If you would like to learn more about the advantages of machine tool probing, contact Bill Griffith (434-978-5670) or your local GE Fanuc sales team.