NX

Divya Engineering Works

Machining specialist realizes significant time/cost savings and enhanced product quality; machine maintenance and production costs cut by 35 percent

Industry Industrial machinery and equipment Business challenges Enhance reliability of data communication between CAD and CAM Provide a more user-friendly environment Produce a high-quality surface finish and dimensional accuracy Reduce design time and machining cycle time Keys to success Editing tools to help reduce cycle time and improve quality Optimized feed rate so material can be scooped smoothly New tool path strategies to reduce machining time and improve surface finish Single platform integration to enhance ease of use

Use of NX helps save wear on machines by enabling optimal tooling path strategy
Starting small and thinking big When Divya Engineering Works (P) Ltd. decided it wanted to expand its footprint in precision machining across the aerospace industry and take on projects that included highly complex shaped components, they turned to Siemens PLM Software and its NX software. Divya Engineering Works, which is located in Mysore, India, 140 kilometers from the information technology (IT) hub of Bangalore, was founded in 1993 with a single computer numerical control (CNC) machine. The original mission was to start a small tool operation for automotive suppliers and precision machined components vendors mainly forging plastic components. Today, with a total of 70,000 man hours of CNC experience, Divya Engineering Works produces cast, machined and molded parts such as blow molds, 3D sculptured machining and electrodes for a variety of industries including telecommunications, electronics and watchmaking, as well as aerospace and automotive (including engines).

Investing in a known quantity Originally, Divya Engineering Works used a manual program for CNC milling, and later moved to other solutions for cycle-time reduction and programming. However, these solutions did not adequately address several key issues, including the need to eliminate excessive machine idle time and the inability to machine complex profiles. The earlier solutions also placed responsibility for accuracy on the operator. Moreover, the approaches lacked standards; they were prone to human error; and data couldnt be re-used. The company decided to invest in a premier solution for computer-aided design (CAD) and computer-aided manufacturing (CAM) that was well known throughout

www.siemens.com/nx

Results Integrated approach to CAD/ CAM reduces machining time by 50 percent Tooling path options save wear on machine and cutting tools High-speed capabilities improve productivity by 40 percent Improved surface finish and dimensional accuracy enhances quality by 50 percent Overall improved processes reduce machine maintenance and production costs by 35 percent Having CAD and CAM on different platforms makes communication difficult and its pretty easy to lose data. By using NX CAD and NX CAM software, which are both on the same platform, we found it was much easier to edit the data in the CAD system. Our communication improved substantially and we didnt lose data. In addition, we realized a 50 percent time savings. S. K. Nagesh General Manager Divya Engineering Works the industry and would give it the ability to quote on a wider variety of jobs, including programs that featured highly complex parts. We decided to invest in the best available software that would meet the needs of all our current and prospective customers, says M. N. Venkatesh, managing director at Divya Engineering Works. When we spoke to people in the tooling industry, both machine vendors, such as Makino and DMG, and machining companies, we received universally strong reports about NX CAD and NX CAM. It was important for us to invest in software that was compatible with what companies in these industries were using. One of the best proof points that NX would be a great choice was the fact that it is being widely used in 3D sculptured machining. That says a lot. Enhancing communication between CAD and CAM There were a number of reasons Divya Engineering Works chose NX for use on its 3-axis milling machine: the company wanted an integrated CAD/CAM solution that would enable seamless communication between the two functions; a userfriendly set of tools that would enhance productivity; and a system that would support high-speed machining and shorten design time while also producing a good surface finish, high quality and dimensional accuracy. The company also sought to diminish unnecessary machine use by having the ability to choose from a variety of tooling path strategies. Divya Engineering Works found that engaging CAD and CAM technologies that werent on the same platform led to a number of problems, including lost data and a lack of user fluency from system to system. Conversely, the company also realized that, if its machining professionals learned two highly integrated applications that used the same platform, it would enhance the users ability to multi-task and make them more efficient overall. The company found additional benefits beyond the advantages of eliminating translation and using a single software system. The modeling tools provided by NX are making it easier than ever to prepare models for CNC programming. The use of synchronous modeling has helped

One of the best proof-points that NX would be a great choice was the fact that it is being widely used in the 3D sculptured machining, that says a lot. M. N. Venkatesh Managing Director Divya Engineering Works These high-precision machines are very expensive and maintaining them involves significant costs. So we dont want to run them any more than is necessary. By providing tool path strategies that track uncut material and achieve a specified chip volume Having CAD and CAM on different without overloading the platforms makes communication difficult tools, NX not only improves and its pretty easy to lose data, says our productivity, but it also S. K. Nagesh, general manager at Divya enables us to reduce our Engineering Works. By using NX CAD and machine costs. We estimate NX CAM software, which are both on the same platform, we found it was much eas- that using the NX products ier to edit the data in the CAD system. Our has cut our maintenance and production costs by communication improved substantially 35 percent. and we didnt lose data. In addition, we realized a 50 percent time savings. S. K. Nagesh Choosing the best path The use of NX also provided Divya Engineering Works with high-speed capabilities that enabled the company to produce a higher-quality surface finish and greater dimensional accuracy compared to its prior approach. This contributed to a 50 percent increase in quality. Using an optimized feed rate helped us scoop the material smoothly and create a high-quality surface finish while also enabling us to complete the job more quickly, says Nagesh. Those are all critical concerns for satisfying our customers as well as keeping up with demand so we can attract and accommodate new business. General Manager Divya Engineering Works

in the direct editing of solid faces in the CNC environment. Developing as-cast models or other derivatives from existing parts is easy, because the programmer simply needs to push and pull on the existing faces. More importantly, the CAM and CAD information is wholly integrated. The master model capability of NX ensures that CNC development data stays associative to the source model. This makes changes and updating easy. In addition, the solidsbased cutting strategies of NX work with complex shapes, so safe and efficient cutting and transition motions on 3D surfaces can be intelligently applied.

Solutions/Services NX CAD NX CAM www.siemens.com/nx Customers primary business Divya Engineering Works (P) Ltd. is an ISO 9001:2000 certified company that provides total solutions for products. Solutions include cast, machined and molded parts for products used in the aerospace, automotive, electronics, telecommunications and watchmaking industries. www.divyaengineering.com Customer location Mysore India Partner Tata Elxsi Limited When we spoke to people in the tooling industry, both machine vendors, such as Makino and DMG, and machining companies, we received universally strong reports about NX CAD and CAM. It was important for us to invest in software that was compatible with what companies in these industries were using. M. N. Venkatesh Managing Director Divya Engineering Works

The capabilities of NX CAM are designed to achieve the highest cutting speeds. High-speed roughing and rest milling keep chip loads constant while minimizing air cuts. Smooth-cutting capabilities keep feed rates high while providing fine finishes. Feed-rate optimization helps ensure that tools are not overloaded, minimizing tool wear while keeping metal removal rates maximized. These high-precision machines are very expensive and maintaining them involves significant costs, says Nagesh. So we dont want to run them any more than is necessary. By providing tool path strategies that track uncut material and achieve a specified chip volume without overloading the tools, NX not only improves our productivity, but it also enables us to reduce our machine costs. We estimate that using NX CAD and NX CAM has cut our maintenance and production costs by 35 percent.

Improving accountability Ultimately, NX CAD and NX CAM technology has enabled us to get a better understanding of how our resources are being allocated, and having that kind of accountability has been critical to allowing us to get the most value out of those resources, says Venkatesh.

Siemens Industry Software Americas +1 800 498 5351 Europe +44 (0) 1276 702000 Asia-Pacific +852 2230 3333 www.siemens.com/plm
2013 Siemens Product Lifecycle Management Software Inc. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. Z6 32445 1/13 A