December 2011
Customer Highlight: SigmaNEST Delivering Results
A recent selection of SigmaNEST CAD/CAM nesting software by Tampa Bay Steel is delivering a substantial return on investment. As the world's leading CAD/CAM nesting software, SigmaNEST delivers unequalled efficiency and speed in terms of material optimization, part cutting and cost estimation.
"We began implementing SigmaNEST just several months ago and are seeing significant and rapid gains in productivity and savings," explained David Carpenter, Engineering Manager at Tampa Bay Steel. "Because we utilize a variety of high-end fabrication equipment including multiple laser, plasma, and waterjet systems – it is imperative that we find a single-source solutions provider to ensure that our fabrication process is operating in the most effective way possible. Increased machine productivity and reduced material scrap is a great benefit and with SigmaNEST we achieve both in a single program."
Founded in 1980 Tampa Bay Steel (Tampa, FL) service center processes and distributes metal products to customers in the agriculture, construction, trailer, and energy industries. Their in-house modeling software is SolidWorks. The flexibility of SigmaNEST allows the company to become more agile and responsive. Similarly Tampa Bay Steel is finding that the software's cost estimation capability allows for more accurate and winning quotes. "Our customers have come to expect quality and quick turn-around. Leveraging best-in-class technologies allows us to concentrate resources on what we do best while leaving part nesting to the experts."
"Today like never before manufacturers across the board are scrutinizing every aspect of operations," explained SigmaTEK Vice President Dan Barr. "From production to cost reduction and job cost estimation, shop-floor applications will have an increased impact on the bottom line. Tampa Bay Steel is an example of an organization taking steps to ensure that its customers continue to receive the quality and service they have come to expect while at the same time improving operational efficiency and profitability. We look forward to solidifying our relationship and playing a progressive role in the company's future manufacturing initiatives."
SigmaTEK Systems and ITT Corporation have combined their most powerful technologies: SigmaNEST, Burny & Kaliburn, to produce the unparalleled UltraSharpTM plasma cutting system. The system has been calibrated to ensure the highest quality in hole cutting.
1. A hole is a hole, right?
Grindstaff: Producing a hole is quite simple with many machines; N_G_X_Y_I_J_ will produce a hole. Unfortunately producing bolt-ready holes is not as simple as cutting a circle in steel. Sidewall imperfections resulting from plasma cutting inconsistencies can render holes useless until they are cleaned up with a secondary process. When you consider what is involved in cleaning up multiple holes, it isn’t difficult to understand how this can have a significant impact on time, cost and quality.
2. What are the most common problems with plasma cut holes?
Grindstaff: Gouging, cylindricity and taper are the three major problem areas.
In gouging, plasma nicks the part sidewall after the slug drops due to arc deformation. This is due to the lead-in being too long or moving into the drop area. The solution can be found in one of three ways: turn the torch off short of lead-in to ramp down the power, use overburn at lead-out or use automatic feedrate ramping at lead-out.
Cylindricity can be adversely affected when the feedrate is too fast. Obviously the solution is to slow the feedrate in the hole based on hole diameter, and use preprogrammed feedrate on these features, which UltraSharp does. In addition, UltraSharp adjusts gas parameters automatically.
Taper is the third issue associated with plasma hole cutting quality. It is caused when the height to cutting surface ratio or gas pressure is not correct. UltraSharp automatically selects the proper cut chart eliminating error in height pierce and gas settings.
3. What are the requirements for UltraSharp?
Grindstaff: A well serviced 3-axis cutting table is the first requirement. Other requisite hardware components include the Kaliburn Spirit Plasma, Inova Height Control, and the Burny control with advanced command messaging enabled. On the software side, SigmaNEST with the HDX module is required. While we are talking about requirements, it is important to note that this process requires no operator intervention to improve performance.
4. Can existing machines be retrofitted for UltraSharp technology?
Grindstaff: Any 3-axis cutting machine that meets the requirements mentioned earlier can be retrofitted with UltraSharp. Customers should work with their OEM or integrator to determine which UltraSharp capable products are needed. The resulting hole quality may vary depending on the condition of your cutting table, so it is advisable to also have the existing machine serviced for optimal performance.
Information
For more information on UltraSharp, please call Scott Grindstaff at
513-674-0005 or email scottg@sigmanest.com
Tech Tip: Obtaining Material Thickness Specifications from SolidCAD Import
Importing a SolidCAD part is much more efficient if the correct material and thickness assigned to the parts are imported as well, rather than having to make corrections after it is imported.
There are two different ways to assign material type in a SolidCAD file:
- Specify the material in the CAD files material property
- Add it in the file properties as a custom property
When a material is not defined in the material property or in the custom file properties, the model setting will default to the last part created. When the material type is defined in the material property, SigmaNEST uses this information as the material type. If a material is defined in both the material property and a custom file property, the custom file property will take priority, provided it has been set in the SigmaNEST configuration. In cases where custom material property is not defined in SigmaNEST, the material property will take priority.
Thickness, unless specified in pcode.txt file (see below), is always defined by the model.
A more advanced approach uses a pcode.txt file (also known as a material look-up file) to redefine materials and setting thickness. The default file location for the pcode.txt file is in the root of the SNDATA folder. For 3D translations, SigmaNEST uses a comma-separated pcode.txt file, like those available for 2D translations. Because many SolidCAD models use characters not valid in a SigmaNEST material name, like commas, it is necessary to rename the material. The two possible formats which can be used:
Material in, Material Out, Thickness
This format works well with SolidCAD file names that do not contain a comma.
'Material In', 'Material Out', 'Thickness'
This format works well with SolidCAD file names which contain commas. Here, single quotes are required around each value in this line.
Thickness is an optional value for SolidCAD files, which will be extracted from the model if not defined. In cases where the thickness is defined, the thickness in the pcode.txt will override the value from the model.
In the example of a pcode.txt file below, AISI 1015 Steel, Cold Drawn (SS) will be redefined as SS with a thickness of .25. AISI 1045 Steel, Cold Drawn will be redefined as MS; a thickness is not defined. Lastly, MS14GA will be redefined as MS with a thickness of .075.
'AISI 1015 Steel, Cold Drawn (SS)','SS','0.250'
'AISI 1045 Steel, Cold Drawn', 'MS',
MS14GA,MS,0.075
