The HITHRU project, now in its second year of activity, is yielding solid indications that its original objectives will not only be met, but may well be exceeded by a considerable margin.

This project combines two leading-edge technologies: high-speed, five-axis machining and Technology Answers' Cimskil™ (formerly called CIMPLEX™) feature recognition programming software. When combined, these technologies provide a system that is capable of producing five-axis parts rapidly and with a minimum of human intervention. The project objective is to develop and demonstrate a high-throughput, five-axis machining system that will program and produce first-article and production parts with a minimum of human intervention (programming and troubleshooting). The productivity improvement target was 50%.

Industrial partners UT-Sikorsky and Cincinnati Machine, and depot partner Warner Robins provided part models and machining best practices to Technology Answers to guide software development.

Cincinnati Machine fully characterized the cutting process dynamics of its Lancer V5 five-axis vertical machining center with a 40-hp, 15,000-rpm spindle (using cutting tools recommended by industrial and depot partners). Cincinnati Machine then used the data to define an algorithm that will recommend axial and radial depth of cut, feed rates, and spindle rpm, all optimized for maximal metal removal rates while avoiding conditions that could trigger chatter.

Technology Answers modified its Cimskil™ product to add automated feature recognition of typical five-axis manufacturing features found on aluminum components for the aerospace industry, add automated selection of manufacturing methods, and integrate the process parameter algorithm developed by Cincinnati Machine. Technology Answers also modified Cimskil™ to allow run time edits of libraries and process parameters, replacing the old system that required off-line edits of C++ code.

The partners selected a feature-rich part from Warner Robins as the test part that would drive software development. Experienced five-axis CNC programmers estimated the test part would require 100 – 120 hours to program with conventional methods and would then require another 10 – 12 hours of shop floor debug time. In a late September technology demonstration, the test part was run through the prototype system, producing a CNC program in less than 3 hours from downloading the model to the output of the CNC program. During October and November, the system will be tested on an additional 20 – 25 new parts, and any software bugs uncovered will be fixed. Parts machined using programs produced by the system will be quality tested to ensure that the optimized processes achieve required quality.

This technology will be available from Technology Answers in 2001. The HITHRU team is now forming a Phase III effort that will extend Cimskil™ technology to titanium aerospace parts and to Cincinnati Machine’s Magnum™ five-axis machine tool.

For more information, please contact Tony Haynes, 734-995-4930.