Which of the following statements is correct? Answer now and learn more
1. When you purchase a sophisticated, high performance CNC machine, it automatically accepts computer aided design (CAD) and manufacturing (CAM) data and produces parts.
2. The manufacturing program created on your preferred CAM system does not need to be translated into the correct cnc control language.
3. Machine downtime is cost effective and has no impact on productivity.
4. The hidden costs of an unreliable post processor are negligible.
Before you go any further, here comes the solution: none of the above statements is correct. Are you now shocked, surprised, angry and/or mystified? That’s good, because otherwise you can’t get any more attention today.
Postprocessors in production – A new code for every order
Okay, that wasn’t exactly fair now, but somehow we have to clarify the topic of our blog post today. Because it’s a problem that many employees in production are not aware of. And when they are aware of it, they often solve it in an ineffective way. We are talking about postprocessors, more precisely about their importance for the smooth implementation of your CAD/CAM data on a CNC machine. Not every control – although it is called the same – can be programmed with the same CAM postprocessor. In this context, you have probably asked yourself more than once why there is no 100%-ready postprocessor, for example for a Siemens 840D or Heidenhain TNC640, especially since the control is used on numerous machines from different manufacturers. In addition, standardization (uniform program heads, program end and the technical program structure) is becoming more and more important.
The triviality of milling – Why postprocessors require individual solutions
Providers of CAM and CAD-CAM systems often tend to trivialize post-processing problems. However, as soon as more complex requirements are encountered, post-libraries reach their limits. As a result, a post-processor program must be individually created and purchased for the user to meet their programming requirements and machine/control options. If you use a post from such a library, you may have to manually modify your G-code programs and lose time setting up the part program.
Die besten CNC-Programmierer wissen auch, wie man mit Postprozessoren arbeitet
It often happens that CNC programmers “hack” the postprocessor to immediately get the code they need for a task. The programmer performs a machining operation and then creates the NC code for the current job, which he executes for milling, turning or cutting. Because the machining that has been done has worked – at least in this case – he devotes himself to the next task and doesn’t realize that he can’t use some of the code that might later be needed for another job. He only discovers the problem when a new job, such as a turning job, is created that has a different code. He then “hacks” himself individually from job to job in order to complete these new tasks. Legend has it that there are companies where dozens of postprocessors have been developed for the same machine. This is not only inefficient, it is also dangerous. There should only be one post for each machine in the workshop. This mail should be adapted to the way your company produces its parts.
Don’t underestimate the hidden costs of an unreliable post processor
Post development is not easy. Most CAM systems on the market today are complex and the script used to generate your NC code can be even more frightening – whether it is used for milling/turning, cutting, robotics or any other purpose. At the end of the day, an investment must be made to get reliable NC programming. We can’t tell you how many companies are neglecting the post processor at best. These companies will spend hundreds of thousands, if not millions, on high-end CNC machines. But it is expected that the post processors will be free.
Individual Post Processing – Optimize Performance with MySolutions
A machine is only as efficient as the software that drives it. That’s why the MySolutions team personally installs your post processors to make sure they work according to your needs. Understanding the complexity of CNC and the limitations of each machine is key to our success. Regardless of which CAM system you work with, MySolutions experts extract the necessary data for seamless translation into your machine park. You have full control over your machine behavior and get exactly the performance you need. If you like the combination of CNC post-processing, G-code verification and multi-vendor machine compatibility, contact us and let us help you optimize your setup.