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78 MMS June 2014 mmsonline.com feature Formed workpieces can be trimmed on a five-axis laser cutting machine, which can also make openings that represent piercings of various shapes. necessary tool paths and perform the remachin- ing on one of the company's three machining centers. QFS relies on PowerShape for the CAD portion of the first step. The "new" geometr y may be derived from updated geometr y files from the customer, or from 3D scans of die or workpiece surfaces. Scanning is often performed with an ATO S o p t i c a l d i g i t i z i n g s y s te m f r o m G O M (Gesellschaft für Optische Messtechnik). Scanning cre ate s a de nse point cloud or tr ia ngulate d m e s h th at c a n b e i m p o r te d i nto th e d e s i g n software. Areas that need to be modified are rendered in a different color, enabling the programmer to select and update the geometry. Often, where there is sufficient stock, the new geometry can be created by "lowering" the existing surface in the Z axis. Tony Goodwill, one of QFS's CNC programmers and expert machine operators, points out that the benefits of using PowerMill at this point are twofold. The speed at which the new tool paths can be generated and optimized is one benefit. The other is the reduced machining time that results from efficient roughing and finishing tool motions in the cut. The Vortex roughing routines are especially important here, because saving time in the rough- ing ste p e nable s the shop to accommodate lengthier finishing routines. Normally, finishing involves close stepovers and light cuts to create smooth die surfaces that require a minimum of handwork. As a further efficiency, QFS will start the roughing passes on the machine while the f i n i s h i n g p a s s e s a r e b e i n g c a l c u l a te d a n d optimized. The same CAD/CAM software also enables QFS to repair and renew press forming dies from the field as a service to customers. Train and SuSTain Mr. Howells is a firm believer that continued train- ing of his workforce is vital to success. The com- pany has an active apprenticeship program, but all employees are encouraged to develop skills in a variety of areas. For example, he has found t h a t e m p l o y e e s w i t h s t r o n g s h e e t m e t a l experience are likely to become the best machin- ists and CNC programmers because they under- s t a n d t h e s u b t l e t i e s o f t h e p r e s s f o r m i n g process. These insights help them embrace new technology eagerly and quickly learn to use it to the best effect. For this reason, the company's two seats of PowerShape and PowerMill are located in a pro- gramming of fice in the middle of the unit that 0614_MMS_QFS.indd 78 5/14/2014 9:53:14 AM