Price-competitiveness + 5axis + hard-to-cut materials = No problem with VERICUT FORCE™
Located in Ham-an, Gyeongsangnam-do of South Korea, DaehanENG is specialized in producing aerospace parts. Since its establishment in 2005, the company continuously invests in the latest technologies and R&D, taking a firm status as a trusted supplier for global aerospace brands. DaehanENG produces 6,700 different aerospace parts. Increasing demands for parts made of hard-to-cut materials, in addition to the steadily falling price of aerospace parts, are a few of the challenges that the company is facing in order to grow further. DaehanENG taps for new opportunities with CGTech’s CNC verification and simulation software, VERICUT, especially the feed rate optimization module, FORCE™.
The declining cost of parts due to increased competition in the market is one of the causes of profitability fall for small and medium-size manufacturers like DaehanENG. More and more companies are seeking a solution to break-through these tough times with productivity technologies, such as automation and lights out manufacturing. DaehanENG mainly produces aerospace parts, defense industry materials, and the fixture is pioneering to adopt the latest manufacturing technologies to increase its competitiveness in the market. DaehanENG thinks the active investment in both automation facilities and software will get it through the rough market situation.
The CEO of DaehanENG Youngsup Kim says, “We win more orders but the profitability is not keeping up the increasing work we do because customers look for better prices. New aircraft demands are increasing the amount of parts that are cut from difficult materials. There’s an immediate need for manufacturing technology that will get delicate jobs done while keeping expenses low. I believe investments in the latest machines and software like automated manufacturing solutions, CAD/CAM, and ERP are critical at this stage to address the challenges we have.”
DaehanENG is one of the pioneering companies to use an ERP system to comprehensively manage production processes, quality control, and sales-related data. The company invested in precision manufacturing capabilities and efficiency enhancement with new 5-axis machining centers. Now their latest interest is on the CNC machine simulation and optimization software, VERICUT.
DaehanENG purchased their first VERICUT seat in 2016. For 13 years the majority of the company’s produced parts were either 3-axis machined or molded, comparatively easier than the recently demanded complex parts which need 5-axis cuts. The need for simulation has also increased. “5-axis cuts are riskier than 3-axis cuts in terms of machine crashes or tool collisions. Aerospace parts are made of expensive materials and the material prices keep rising. I had to save time and keep the cost to the minimum. I believe that a perfect NC program can do it for me”, Youngsup Kim explains.
DaehanENG simulates all 906 jobs done by its 5-axis machines and all of the 3-axis products as well using VERICUT verification, multi-axis, and AUTO-DIFF modules. The AUTO-DIFF module compares a CAD design model to a VERICUT simulation to automatically detect differences. After experiencing how VERICUT simulation improves the manufacturing quality, DaehanENG is testing VERICUT’s feed-rate optimization module, FORCE. FORCE analyzes cutting force, spindle power, chip thickness and maximum feed-rates to come up with the optimal constant feed-rate, cut-by-cut.
Quality team manager, Youngjung Kim, explains, “If a normal cutting condition is applied to hard-to-cut materials such as Titanium and heat-treated steels, it will slow the whole process down significantly. FORCE helps to speed up difficult cuts so we keep or even enhance our competitive edge in the market.”
The company ran a few FORCE tryouts with CGTech’s technical support. In one test, a SUS (17-5PH) plate production time has decreased by 30 minutes from 4 hours 10 minutes to 3 hours 40 minutes by optimizing only one tool (T23). In another test, the production time of a large aluminum plate has gone down from 13 hours to 11 hours and 30 minutes, saving one and a half hours per part.
DaehanENG, making active investments to improve both the manufacturing technology and price competitiveness, targets to digitalize all of its production processes using CAD/CAM software and management systems like MES and ERP. CEO, Youngsup Kim, says, “In order to lead the market, we have to keep our technology at the top level with an accumulated manufacturing database. Technology capabilities and management flexibility will be achieved through digitalization and it will take the business further.”
This article was published in MFG Korea, April 2018