CAM-POST Completes FMI’s “Best-in-Class” Manufacturing Software Tools

In 2003, Forest Machining Inc. (FMI) upgraded to CATIA V5, thereby, employing state-of-the-art CAD/CAM programming and verification systems. To complete the “best on class” software package, FMI adopted the leading NC post processing software development tool in the industry, CAM-POST by ICAM Technologies Corporation (ICAM).

FMI selected CAM-POST because it is simple, easy to use and produces advanced, customizable and reliable NC post-processors. CAM-POST also offered FMI direct product integration within CATIA V5 for improved process efficiency, while equally supporting FMI’s additional CAD/CAM system requirements. This provides a single, common platform to meet FMI’s manufacturing process standardization initiatives.

“30% of the jobs we have completed make extensive use of 90 degree heads, in 5-axes machines, and we need a post that could handle that with reliability”, Said Dave Frank, NC Programming Lead at FMI. “All the jobs are checked using verification software before releasing to the shop, so the post must be reliable - errors are unacceptable.”

CAM-POST supports all the macro post word variables used in FMI’s former post-processor. In addition, the new post-processors can be easily enhanced with ICAM’s unique macro debugger - an invaluable coding tool that provides FMI with improved productivity and a competitive edge in the marketplace. The use of CAM-POST’s advanced “look ahead” capabilities enabled FMI to optimize multi-axes CNC performance.

The goal of FMI management was to create an environment where post-processors can be developed using a single common post database shared by all NC programmers, a feature inherent to CAM-POST. A single central post database ensures the use of uniform commands with consistent input and output that is independent of the programmer and, or the CAD/CAM system. Should a modification or fix be required for any post, it is done to the main post database; thereby, allowing all programmers to benefit from the new capability.

Some of FMI’s machines take centerline data instead of G-code. Posts are indended to read CL data and output G-code. Working together with ICAM’s support, FMI was able to read CL, manipulate it as needed and output CL data configured precisely for those machines. The post can break the program automaticly, where FMI wanted to, into the right size for machine memory.

The new CAD /CAM systems, on large hard metal parts, can generate days of motion with a single operation. FMI configured the post to detect in cut time, at programmer controlable intervals, retract do a tool change, run failsafe motion, and re-enter the part.

FMI has several nutating head machines that make use of the post rotary turn around capability, which will select the best position when there are 2 possible machine positions to satisfy a tool axis, and also automaticly retract, unwind and reenter the cut at the programmers controlled parameters.

FMI Benefits when implementing CAM-POST  

• The ability to create a post database where FMI could provide common instructions that both new hires and outside programmers can easily follow for consistent results.
• The ability to use the same APT source and processes to any applicable machine in the shop.
• The ability to rotate programs, change gage lengths, optimize feed rates, change machines by the shop floor NC coordinator without the need to interrupt the programming staff and re-process the program through the CAD/CAM system.
• Consistent tool change motion with tool data messages motion to the tool checkpoint, with programmer controllable clearance planes and target.
• Full 5-axes failsafe motion including pencil tool and bell cutters. The post looks at the cutter statement and the machine rotary axis limits then generates the appropriate tool path.
• Consistent “end of tool motion”, where the post detects the current tool axis, retracts up the tool axis to the clearance point and proceeds to the tool change position.
• Intelligent alignment blocks, or safe restart blocks, triggered automatically by the CAD/CAM system's instruction messages and PPRINTs.

“I made extensive use of the posts ability to both read and write to the hard drive, and its look ahead ability. Reading gage length files. Writing program summaries with tool, time and travel limits. Writing listing of only the program messages, and the time each individual pocket, or operation takes and time left to the next tool change - automaticly.”

“I found that the CAM-POST product was able to do everything I wanted to do and even more. The application staff is extremely helpful, knowledgeable, supportive and professional. In times of crisis, the sales and development team quickly responded to our needs.”

“FMI’s move to ICAM’s technology and support resources ensures our manufacturing infrastructure is operating at peak performance. This allows FMI to consistently meet the operational and competitive effectiveness that our valued Aerospace customers demand,” says Dave Frank, NC Programming Lead at FMI.

About Forrest Machining

Operating out of a 350,000 ft 2 manufacturing and assembly facility located near L.A . in Valencia California, Forrest Machining Inc. (FMI) is a world-leading provider of machined parts and subassemblies to major companies in the international aerospace community.

FMI’s NC department has over 50 machines punctuated with 18, 5-axes multi-spindle gantries, some of which are over 150 feet long. FMI operates approximately 12, 5-axes single spindle machines and over a dozen specialty 5-6 axes machines with nutating heads, tilting heads / contouring table combinations and honeycomb and horizontal machines with indexing tables.

FMI specializes in oversize titanium, inconel and aluminum alloys that require oversized 4, 5 and even 6 axes machines. Parts of this complexity require intuitive manufacturing methodologies, planning and exceptional efforts from experienced NC programming personnel.