SERVICES

OUR SERVICES

Below are some of the many services we offer:

Manufacturing Services

SWSTech uses newest generation milling machines. As there are

• Hermle C22U (parts up to D450xH370mm / interference circle D620mm / travel: X450xY600xZ330mm)
• Hermle C40U (parts up to D650xH500mm / interference circle D1030mm / travel: X850xY700x500mm)
• Hermle C42U MT with integrated turning functionality (parts up to D800xH560mm / interference circle D1030mm / travel: X800xY800xZ550mm)
• …and more

All machines are characterized by high dynamics and high precision. The linear axes X-Y-Z are moving the spindle head, while the two rotary axes are turning and swivelling the work piece about the A and C direction. The linear axis positioning is controlled by direct measurements on glass scales.

The machines are particularly configured for maximum accuracy and high dynamics. Manufacturing is carried out at almost constant temperature conditions.

With these machines we cover tiny parts of a few millimeters up to parts of 1m diameter or side length.

Apart from the machining resources, process and application know how are most important for precision applications. Just to mention product specific fixture techniques, the right sequence of manufacturing steps, or implementing additional work piece treatments. For example stress relieve treatments are frequently necessary. Besides, dimension measurements might be necessary to allow for an adaptive finish machining.

This explains, that apart from the technical infrastructure, the manufacturing experience of the SWSTech team is a key factor for successful Precision Machinery. The involvement of all necessary competencies into our manufacturing processes and the close co-operation between engineering and workshop let us get the best results out of our machines.

NC-Programming / 5-Axis-Technology

The SWSTech-Team has a long standing experience in the field of NC-programming of 5-axis machines. Our expertise in milling covers the following:

• Preparation of customer data for best use in the respective CAM system / Reverse Engineering
• NC-programming with our CAM-Software
• Development of postprocessor software with machine specific and process specific features
• Tool selection and tool optimization
• Machining of various materials

We have profound user experience and know how of ConceptsNREC MAX-PAC software (impeller and blisk milling), UNIGRAPHICS® CAD/CAM (generic NC programming solutions) and CGTech VERICUT® (simulation and optimisation).

We emphasize on the use of 5-axis technology. This technology enables a free positioning of the tool in space by moving three linear axes and a free orientation of the tool towards the work piece by moving 2 rotational axes. This way, e.g. free form surfaces can be machined by driving all axes simultaneously. Alternatively, by changing fixed axis positions a multi side machining of complex parts is possible in only one fixture.

Apart from NC programming of parts, which are manufactured on the premises, we offer customers the NC programming service for use on their machines.

The NC-programming projects often have objectives beyond standard applications:

• Time- or tool cost optimization
• Initial programming of a customer part on a new machine or with a new CAM software (turnkey)
• Introduction of new milling strategies into existing customer processes

SWSTech may offer to make a prototype for program testing and optimization as part of the project. The prototype manufacture takes place on SWSTech machines or on the customer’s machine.

Furthermore, we offer consulting services for systems used by SWSTech and for process related inquiries. For the ConceptsNREC MAX-Software we are official representative which involves Sales and European Software-Support. We are official reseller of CGTech Vericut® in Europe.

Project Management

Many of the components, modules, or manufacturing processes produced or developed by SWSTech reach a degree of complexity that requires project management. Only by means of a professional project management timely execution and high quality standards can be assured. In addition, in development projects the project management is responsible for status controls, customer information, and design reviews.

Important clients where SWSTech takes on project management assignments belong to the space industry or the field of manufacturing development.

SWSTech accounts for the project management requirements by the assignment to only experienced project engineers and through corresponding management processes. Just to mention project planning and project controlling processes as well as the generation of quality documents like manufacturing inspection plans and measurement reports.

Reverse Engineering

The generation of CAD surfaces from coordinate measurement data can produce significantly different results. For best machining, surface entities have to be structured and generated in a way that they match with the machining strategy. E.g. smooth surfaces and short cycle times can be achieved by flank milling or by using form cutters. For this purpose a particular geometric construction of the surfaces – for example as ruled surfaces – or a particular geometric construction of their boundaries is necessary.

The re-engineering of surfaces is preceded by the measurement of the hardware. We can measure the part on the SWSTech coordinate measurement machine or have it measured externally by tactile, optical or tomographic methods.

The scanned points or point clouds are transformed by surface approximation into geometric entities that best fit the manufacturing requirements. We generate the entities needed for manufacturing, complete solid models, or derive the technical drawing according to the client’s demands.

The re-engineering of geometric entities may also be of an advantage for existing CAD models. Most frequently the original surface entities in CAD models are trimmed or blended in such a way that a time-minimized machining is not possible. In this case existing geometric entities should be transformed into new elements that suit best the machining requirements.

Cycle Time Optimization

Within the devolpment of milling processes the customer most frequently lays emphasis on cycle time reduction. Therefore, SWSTech is continuously dealing with cycle time optimization issues and has already spent a lot of efforts into this topic in the past.

The optimization process can be divided into the following sub tasks:

• Development of a suitable machining strategy
• Definition of the degree of automation and of the auxiliary equipment needed
• Definition of the clamping concept on the machine tool
• Adjustment of the roughing process to the overall stability of the configuration
• Optimization of material removal and idle runs during roughing (Vericut®)
• Development of a finishing strategy taking the geometry constraints into account; often 5-axis simultaneous milling strategies form part of the process
• Selection or design of finish cutters
• Programming of finish paths with smallest machine axis acceleration values, avoiding idle runs, and with reduction of axis compensation moves during 5-axis simultaneous milling
• Optimization of tool change sequence

A time optimization always requires a program testing and optimization run on the respective machine or a similar machine that the process is developed for. If such a machine should not be available in SWSTech it is possible to have the tests carried out on the customer’s machine.

SWSTech provides complete process documentation. SWSTech may demonstrate the final process on the customer machine on demand.