February 2009 eNews

On-machine gaging knocks out variability in mold-making

On-machine gaging (using PC-DMIS NC Server on-machine metrology software) has become an integral part of Badger Meters’ manufacturing processes for producing injection molds. In doing so, the Milwaukee, WI, company has eliminated a sometimes elusive source of variability when critical metering components are manufactured.

By reducing scrap and rework, the manufacturer saved time and money. This has translated directly into improved service life and metering precision for customers in this competitive market.

Badger Meters uses on-machine gaging software in conjunction with a Micron HSM 400 high-speed machining center that produces precision mold cavities and inserts from hardened steel. This product allows the users to both create measurement-probing routines and analyze the results off-line in the same CAD-based environment used by the CMM software.

Having interoperable Enterprise Metrology Solutions (EMS) software also makes it possible to share programs and measurement data between the machining centers and CMMs on which PC-DMIS is running.

This approach, which minimizes any impact on cutting time, works like this:

A post processor turns the measurement routines into sequences of G and M codes for driving a spindle probe.

The operator loads the sequences into his machine tool and executes them as he would any other program.

During execution, the probe takes each point and sends the results over a network connection to a file on the remote computer hosting PC-DMIS NC.

Once it has finished probing, the CNC machine resumes cutting. Meanwhile, PC-DMIS NC Server opens the file and uses the PC-DMIS evaluation engine to analyze the point data and report on the features and dimensions of interest. It also stores the results in the DataPage SPC database for on-going process analysis and improvement.

The goal of on-machine metrology at Badger is to make sure that the component matches the CAD model as closely as possible before the component leaves the tool room. When it doesn’t measure up, adjustments are made to the manufacturing process immediately.

As a result of the capabilities Badger has gained using on-machine metrology, the company has been able to more quickly adjust tooling dimensions to improve mold shut-off, critical molded part shrinkage factors, and mold-to-mold variability. This approach is also helping to reduce product development cycles to get new and better water meter designs to market faster.

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Wilcox Associates Inc.

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