CimatronE Cuts 5-Axis Cycle Times by 50% for Kalyani Engineering Works

Pune - Cimatron Limited announced that Kalyani Engineering Works, an established supplier of complex parts for the aerospace and defense industries in India, found that CimatronE yielded a significantly lower cycle time than other major 5-Axis CAM solutions.

"As a leading supplier for the aerospace and defense industries, our customers expect extremely low cycle times even when we produce the most complex, high quality parts," said Mr. Makharia, Founder, Chairman and Managing Director of Kalyani Engineering. "We have recently investigated the major CAM systems on the market. None of the other systems matched Cimatron's built in CAD for manufacturing capabilities and none of them got the job done in the required time frame."

Kalyani Engineering Works is a major manufacturer of spares, components, sub-assemblies, impellors for pumps, compressors and other engineering equipment based in Ghaziabad NCR New Delhi, India. They serve the needs of the fast paced Aerospace, Defense, Railway, Heavy Engineering, Petrochemical/Fertilizer and other industries requiring high quality components.

Kalyani operate several 5-Axis milling machines, including DMU's 100 Mono Block and DMG's 60T machine. CimatronE is their exclusive CAM software for all milling (3-5-Axes). Kalyani has been a CimatronE customer since 2002.

Recently, as part of a project to manufacture turbine blades, Kalyani requested demos from various suppliers of cutting tools. Each cutting tool supplier used a different type of CAM software and presented their best possible cycle times.

"Where other CAM software struggled to program the turbine blade with a cycle time of less than three hours, CimatronE succeeded in achieving a cycle time 50% less for the same part," said Makharia.

Kalyani's 5-Axis work often involves parts that stretch the limits of what even the most modern machines can do. In order to meet these demands, Kalyani have relied on CimatronE's built in and highly integrated CAD functionality.

"The wealth of CAD tools inside the 5-Axis application allows us to significantly increase our control of the machining process," said Makharia. "Using extensions and curves, as well as other CAD functions, we can use our machines to cut in ways that would not have been possible otherwise. This can allow us to manufacture geometries we would not have been able to manufacture, or to improve on our existing methods in order to increase surface quality."

Newly released enhancements, in version 9.0 of the software, attempt to maintain CimatronE's record for fast cycle times, while enabling an even higher surface quality.

The CimatronE 9.0 Impellor Roughing Application is designed to meet the aerospace industry's most challenging demands on complexity, while minimizing calculation and cycle times. New enhancements to the impellor roughing application provide better tool orientation and control, especially for tapered cutters. Additional features provide the option to smooth the toolpath orientation and accurately define depth cuts. Stock consideration allows the application to minimize air cutting, optimize links and apply axial transformation to shorten calculation time.

Version 9.0 also enables the user to control the entry points of the tool path, leading to higher levels of surface quality when machining complex geometries like blades and impellors.

Spiral cutting capabilities have also been strengthened in CimatronE 9.0, allowing users to automatically redo the first and/or last pass to improve surface quality and reduce machining time.