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| “We have specific ways, which are proprietary, that we have to do things here and we're not limited by some software engineer's belief that, 'according to the machinist's handbook, this is what they should be doing, so let's program it in so they don't ever make a mistake.' Happily, Mastercam gives us the flexibility to machine parts our way.” |
- Michael Kurkulonis, Owner, Poplar Hill Machine
Conway, MA |
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In light of the rollicking economy and the shift of many types of parts and even entire industries going to other countries for production, many of the job shops here have had to evolve in an upward spiral of innovation to rise to the top. In those that are thriving today, three concepts emerge as common denominators: automation, sophistication, and flexibility. |
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One of the problems with a former CAD/CAM software package Poplar Hill was using was that John, the programmer, couldn't specify the entry/exit motion, where to start and stop, or how to machine certain features. It had a number of preset strategies and when all failed, it either plunged into the part or failed completely. No one, including the developer, could relay to John what the formulas for these strategies were. This made programming very difficult at times. Other shops have tried to take on Poplar's specialty microwave parts because at first glance, they appear rather simple. But, the customer rejects them because of the tiny burrs and little lips and miniscule edges that they can't get out, not knowing how to machine them and not realizing that their CAM package could be limiting them by almost doing the thinking for them instead of letting the programmer intercede. |
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Since he started his business in his garage in 2004, Mike's business strategy has been to use the most advanced machine tools and automation to manufacture high-tech parts for specialized industries. Applying that philosophy and getting A-plusses for customer satisfaction scores, he quickly grew out of those quarters. In addition to the original horizontal CNC, several new CNCs are humming in the new building, all in keeping with his automation and "one-op complete" mandates.
Carefully chosen machines from Hurco, Kitamura, Brother, and Okuma are on the shop floor. At a nearby PC station, CNC Programmer John Hill uses Mastercam X4 CAD/CAM software (from CNC Software Inc., Tolland, CT) to execute prototype designs and generate reliable, efficient cutting toolpaths for the various machine tools.
Microwave radio telecommunications is one of the leading areas of new business at Poplar Hill. It's an emerging field requiring some of the most challenging parts the company makes, such as components with waveguides. Microwaves are electromagnetic waves with wavelengths ranging from as long as one meter to as short as one millimeter, or equivalently, with frequencies between 300MHz (0.3 GHz) and 300 GHz. Waveguides direct or channel these invisible microwaves. Mike has produced components with as few as one waveguide, to ones with hundreds for his customers. He believes that microwave radio telecommunications will replace cable-driven communications as it brings advanced technology to remote parts of the country and the world, and plays an increasingly important role in the defense industry.
"We typically use 0.005 in. to 0.015 in. diameter end mills to make most of these waveguide parts," says Mike. "Many of the features in these parts cannot have burrs and we're not allowed to deburr them. Wherever the electromagnetic wave for the microwave is traveling, it has to have sharp, crisp edges everywhere."
One of the problems with a former CAD/CAM software package Poplar Hill was using was that John, the programmer, couldn't specify the entry/exit motion, where to start and stop, or how to machine certain features. It had a number of preset strategies and when all failed, it either plunged into the part or failed completely. No one, including the developer, could relay to John what the formulas for these strategies were. This made programming very difficult at times.
"With Mastercam, all that went away," says John. "I'm now able to tell the software exactly where to start and end, what entry/exit motion to use, and how to machine it." That's made a huge difference because as Mike says, "we're not allowed to deburr these parts."
Other shops have tried to take on these parts because at first glance, they appear rather simple. But, the customer rejects them because of the tiny burrs and little lips and miniscule edges that they can't get out, not knowing how to machine them and not realizing that their CAM package could be limiting them by almost doing the thinking for them instead of letting the programmer intercede.
"That's been the biggest plus for Mastercam here. We have specific ways, which are proprietary, that we have to do things here and we're not limited by some software engineer's belief that, 'according to the machinist's handbook, this is what they should be doing, so let's program it in so they don't ever make a mistake.' Happily, Mastercam gives us the flexibility to machine parts our way."
The waveguide parts must come off the machine ready to be assembled, ready to be plated, and sometimes shipped directly to inventory -- bypassing the customer's quality control department. The machines of choice at Poplar Hill for this work are the Kitamura MyCenter-250s and an Okuma MA-400HA Space Center horizontal machining center with an automated tool changer that carries 198 different tools and an automated pallet exchanger with 12 pallets that allows operation on a 24-hour basis, every day of the week. Mike purchased the Okuma in 2008 after a thorough examination of alternate machines. The Okuma's accuracy, speed, and range of functions met the criteria necessary to machine the waveguide and other fussy parts at the company. The high speed machining in Mastercam has complemented the inherent design of the Okuma and Mike's "lights out" operation. |