3-D Solutions has the answer for
Cummins
When Cummins Engine Co.’s new Signature 600 turbocharged diesel
engines start powering the biggest semi-trucks, their range and exhaust emissions
compliance will be a function of the work of a small but technically-advanced foundry
pattern shop in Wisconsin, USA, called 3-D Solutions. On those 600 hp engines is a new
turbocharger designed by Holset Engineering Co. It is assembled with as-cast rather than
machined components, a decision made to hold down costs as well as to take advantage of
steady improvements in foundry quality assurance. |
PowerMILL supporters Dennis Arrowood (left) and Mike
Marcott of 3D Solutions |
Dennis Arrowood, 3-D Solutions President, and Mike Marcott,
Arrowood’s business partner and the company’s Head of Engineering, had seen
similar parts before but this turned out to be more complex than anyone anticipated.
"We expected to do this job with two cores and those just for the volute,"
Arrowood said. "This one ended up with twelve tooling elements in all. We had to make
twelve separate models, get them approved, and machine twelve separate shapes for the
green sand moulds and the cores."
With such complex geometry, 3-D Solutions needed state of the
art CAD and CAM. "Delcam provides the package best suited to do the toolpaths and the
necessary design work specifically needed in pattern making, such as fillets, corner
rounding, parting surfaces etc.," said Mr. Arrowood. "After doing the Holset
casing, we know we can cut the most complicated parts."
"The main advantages of PowerMILL for 3-D Solutions is
that complex 3D shapes can be machined much easier than before," said Mr. Marcott.
"The chips hit the shop floor fifty percent faster and, because it’s so easy to
use, we can train new machinists very quickly."
One part of the foundry pattern tooling for the new Holset
turbocharger |
"One of PowerMILL’s great features is optimising
tool length," he continued. "If a machinist uses too long a tool it can
potentially destroy the job. PowerMILL optimises the toolpath for a given tool length by
recognising the desired length of the tool. All segments of the toolpath that would need a
longer tool are then automatically deleted." "PowerMILL also allows us to maximise the accuracy of our machine tools.
Surface finishes are better so there is less hand work. That also helps make more accurate
parts," Mr. Marcott added. "All this is of great benefit to our company and our
customers because we can get more work through the shop and hit targeted delivery
dates." |
