Modern Machine Shop

SEP 2018

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Safe CNC Programming for Bold Machining Modern Machine Shop 91 off the ground with a team of creative and dedi- cated craftsman as the flight crew. CAD/CAM Contributes to Confidence When Flying S made the move to its new facility across the road, one of the people who came along was Peter Bowman, a young machinist who brought his extensive CNC machining and programming knowledge with him. Still in his 20s at the time, Mr. Bowman was a graduate of the Machine Trades Tool & Die Advanced Manufacturing program at nearby Vincennes University (where his father, Doug Bowman, has been teaching manufacturing curriculum for more than 25 years) and was transitioning from a 3-year Master's Apprenticeship Program at the Haas Automation factory in California. He was hired in 2010 because of his familiarity with a broad range of CNC equipment, his connection to Vincennes, and proficiency with Mastercam CAD/ CAM software, which is used extensively both at the University and Flying S. Mastercam (from CNC Software Inc., Tolland, Connecticut) was an appropriate choice for Flying S because the modular nature of the software enabled the company to acquire the level of capa- bility that was required at the time. Starting with basic 2D and 3D programming, the shop expanded its programming tools to accommodate multi- axis systems, including lathes with live The main machining area of Flying S's manufacturing complex houses several cells of similar machines. This row of three-axis machining centers is adjacent to the five-axis machining cell. Because all the machines have the same brand of CNC (Haas) programmed with the same CAD/CAM software (Mastercam), the shop's team of machinist/programmers is adaptable, flexible and capable of operating virtually any machines assigned to them. ordinary country fence, is the Shaw farm, which has been in the family since the 1700s. When David and Penny Shaw started Flying S, they decided to return and locate the new business there. Striking out on their own as founders of an aerospace engineering and consulting firm was a natural move for the Shaws because their work experience prepared them well. David Shaw had been involved in aircraft design and production at Cessna Aircraft (Wichita, Kansas) and in compos- ites manufacturing at Scaled Composites (Mojave, California). Penny Shaw had a background in busi- ness management and company development. Meanwhile, the farm continued to operate as a profitable and environmentally sustainable producer of beef cattle. In fact, the company name, Flying S (the S is for Shaw), is represented by a logo that intentionally features a traditional branding iron design for a letter with wings, but in this case, they resemble both aircraft wings and cattle horns. From the start, the Shaws intended to design and build aircraft using advanced composite tech- nology. However, because businesses in the nearby communities supported a workforce with skills in machining and metalworking, their first step into manufacturing was buying a well-used, knee-type milling machine. Venturing into composites came later, when skills for working with composites could be developed in house. By then, Flying S was

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