SHOP SOLUTIONS s Problem Solving on the ShoP Floor SOLUTIONS s Problem Solving on the ShoP Floor Kevin Hjelmgren (left) and Gary Warlow wote progams using GibbsCAM macros to …

May 2015 | AdvancedManufacturing.org 53

Programming, Macros Automate CAM’s Reach

A t Wilson Tool International, two senior CNC programmers

demonstrate how management flexibility in executing their

jobs has greatly improved productivity from the time orders are

received to the completion of machined parts to fill the orders.

Read more, P54

Welding Training SystemGives Instant Feedback

A LMACO (Nevada, IA) uses the LiveArc welding per-

formance management system to provide immedi-

ate training feedback to welding operators to track their

performance—both in the simulation and live welding

modes, allowing them to correct issues quickly.

Read more, P62

Presetting System SavesDie-Maker Time, Money

H. Beck Machinery Ltd. (Windsor, ON, Canada) special-

izes in high-accuracy, large-scale CNC custom machin-

ing using 10 large machines from boring mills to a six-axis

Droop + Rein mill and a five-axis Fidia machining center.

Read more, P131

sSHOP SOLUTIONSProblem Solving on the ShoP Floor

Kevin Hjelmgren (left) and Gary Warlow wote progams using

GibbsCAM macros to automate processes at Wilson Tool’s

bending division and make parts as needed in “lots of one.”

Zoller tool management systems have saved H. Beck Machinery

machine time and permitted longer untended machine operation

in its machining of auto stamping dies from roughing to finishing.

Easy-to-use, the Miller Electric LiveArc system provides immediate

feedback on performance to ALMACO welding operators, both in

simulation and live welding modes.

54 AdvancedManufacturing.org | May 2015

It’s a case of how a company’s success can be traced

directly to management’s efforts to improve productivity and

cut costs by hiring the right people and equipping them with

the most advanced CNC programming system.

Wilson Tool is the world’s largest supplier of standard and

custom tooling and accessories to the punching, bending,

and stamping industries with manufacturing facilities in the

US, UK, and Canada, and distribution and support facili-

ties worldwide. At its headquarters campus in White Bear

Lake, MN, Wilson runs its business with SAP enterprise

management software. It operates hundreds of machine

tools supported by 10 networked seats of GibbsCAM CNC

programming software from 3D Systems, formerly Gibbs and

Associates (Moorpark, CA). GibbsCAM is frequently used

by machinists on the shop floor as well as by seven full-time

programmers at Wilson’s three divisions.

The autonomy that Wilson management provides its

employees has led to initiatives that have been accepted

and adopted, including those that began within the CNC

programming group in the press-brake (bending) division.

Kevin Hjelmgren had been at Wilson for two years when

he transferred into CNC programming seven years ago. He

began using GibbsCAM the way other programmers showed

him. “We would model the cutting tool, get our tool position

from the software, then do manual G-code programming. We

were doing very simple things with the software, using it only

as support, but I had been trained and knew its capabilities,”

Hjelmgren said.

Hjelmgren began using GibbsCAM for actual program-

ming, and when another programmer saw results, he began

using it. Slowly, the programmers began implementing the

software, first for programming, then for building models of

the machines, models of the tombstones for the horizontal

mills, and models of the tools and holders, to enable accu-

rate toolpath verification and machine simulation.

“It has been great for programming horizontals, because

I have to get tools into very tight spaces,” said Hjelmgren.

“Being able to watch a program run on my computer has

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been a huge benefit. With machine simulation, I see

if something is not going to work and fix it there,

instead of discovering errors at the machine.”

The press-brake division makes the largest of

Wilson’s tooling, typically punches and dies for press

brakes, and so have the largest machines. Of its 26

CNCs, 15 are vertical mills, six are grinders, and five

are horizontal mills with 31.5 × 31.5" (800 × 800-mm)

tombstones. Although the division manufactures a

standard product line, much of the work is custom,

made to order. Hjelmgren said that GibbsCAM has

helped to get some of that work. “Our designers

may come to us with a technical job, and ask if we

can make it. I open their SolidWorks model directly

in GibbsCAM, run toolpath on it to ensure we can

make the part and give them a close approximation

for quoting.”

A feature of the software that programmers rely on is sav-

ing machining processes for reuse. A process incorporates

the type of feature to be machined, tools used, machining

style—all the variables a programmer would need to specify.

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This press brake is shown equipped with a Wilson punch holder and

single, long gooseneck punch clamped in place. The division makes

standard and custom punches, dies, and holders. The company

has a network license of 10 GibbsCAM seats used by programmers

at three divisions and machinists in the shop.


Later, the programmer can recall the process and use it as is

or, if there is an ECO, change the affected variable. The pro-

gram is automatically regenerated. “This has saved us a lot

of time and it has helped with changes we are making in our

work flow, for which I’m reprogramming around 200 parts.”

Until last year, the work flow using the horizontal mills was

batch processing—making lots of 30–50 parts and keeping

an inventory. Scheduling mills for custom jobs, which arrive

daily, was a challenge. Furthermore, because of the schedul-

ing system, programming requires specifying the tombstone

and angle of rotation (tombstone face)—B0, B90, B180 or

B270—for machining. However, programmers can’t predict

which tombstone or face will be open next. To tackle the

problem, the press-brake group decided to move from batch

processing to “lots of one,” making parts as needed, which

was enabled, in part, by the work of another programmer.

“With machine simulation, I see if something is not going to work and fix it there, instead of discovering

errors at the machine.”

Gary Warlow, with 22 years’ experience at Wilson Tool in

England, transferred to Minnesota in 2011, and began using

GibbsCAM two years ago. He learned it quickly, in part be-

cause it is easy to use and processes are easy to set up. Then

he began writing GibbsCAM macros, application program

interfaces that use a specific language provided to GibbsCAM

users. Gibbs writes the code that automates GibbsCAM func-

tions, and maintains a user wiki with the macro commands

to use the functions, but macros use a specific syntax or

sequence, and become complex in multiaxis programming.

Warlow has years of experience in writing macros for

other applications and has even written macros to auto-

matically model parts with SolidWorks. He learned to use

the GibbsCAM language to automatically program many

repetitive tasks, including selecting and sizing geometry,

specifying tools, and running processes.

Management recognized what he was doing, and initiated

a roll-out of automation based on his macros. Moving to

“lots of one” is one of the projects. Warlow writes dynamic

GibbsCAM macros that call up and incorporate the ap-

propriate part programs generated by Hjelmgren, but the

initial rotation angle is output as a variable, letting a machine

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SHOP SOLUTIONS



GibbsCAM generates a setup sheet to inform operators

of the program number, setup, tools, machining operations,

and run time. When the program gets to the variable, it calls

subroutines and waits for the operator to enter tombstone and

face identifiers. All operations are loaded as a G55 (initial coor-

dinate system), but the macro outputs a G56 (new coordinate

system) at every rotation, dynamically updating location.

Another project initiated through Warlow’s macros goes

much farther, and incorporates data generated by the SAP

system. When an order is entered, data about the parts are

collected. The SAP system can generate a flat file or data

file with coded information about geometry and dimensions.

The system is set up to generate a bar code with the job

order. The press-brake group integrated bar-code readers

with GibbsCAM workstations, and Warlow wrote macros that

read the part number from the bar code, open GibbsCAM,

and model the part. The macros run in the background, do-

ing mathematical and trigonometric manipulation on the SAP

flat file data, to generate values that populate the required

variables. It then calls the appropriate saved tools and

machining processes, machines the part, generates the part

program, post processes the file, and outputs a setup sheet.

“It takes about 30 seconds for all this to happen,” Warlow

said, “That’s faster than opening a SolidWorks file.”

The press-brake division selected 26 product families

for the initial automation project. “Every dimension is avail-

able for those product families within the SAP data, and we

completed the project in February,” said Warlow. “Now, our

ongoing project is to automate the rest of the families. Not

all products have a flat file, but we’re working on that, so for

these parts I have macros stop with drop-down menus, and I

enter the data off a print.”

With the progress made, Gary Warlow expects automa-

tion projects to go division-wide at all press-brake locations.

He is now training two programmers on macro development,

one in his own division, for backup, and one in the punching

division. “I’ve been meeting with the punching group, and

they want to change their manufacturing process, develop

SHOP SOLUTIONS


what we’ve done, and even go further,” Warlow said. “The

GibbsCAM macros are fantastic. It’s unbelievable what you

can do with them. I don’t know everything, but I’ve gone a

long way with them.”

For more information from 3D Systems, formerly Gibbs

and Associates, go to www.gibbscam.com, or phone

805-523-0004.

Continued from P53

Welding Training System Gives Instant Feedback

ALMACO (Nevada, IA) uses the

LiveArc welding performance man-

agement system to provide immediate

training feedback to welding operators

to track their performance—both in

the simulation and live welding modes,

allowing them to correct issues quickly.

ALMACO is a manufacturer of custom-

built agricultural equipment such as

combines and planters for the seed

research industry. The company dates

back to 1882, but the ability to include

the latest technology in its products is

what has helped ALMACO grow and

thrive today.

“We have the ability to turn concept

to reality very quickly with high quality

and efficiency,” said Chris Mann, senior

manager at ALMACO. “We devote a

lot of resources and time to meeting

customer needs and to providing them

with new and high-quality products.”

Achieving that quality means rigor-

ous training programs for newly hired

welding operators. Training for AL-

MACO’s welding operators previously

consisted of eight hours a day of weld

coupon work for several days. A train-

ing technician was required to inspect

their progress and give feedback every

half hour or so.

The company wanted a training

method that would be more efficient,

and save money in training time and

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coupons. They began using the LiveArc welding perfor-

mance management system from Miller Electric Mfg. Co.

(Appleton, WI), an advanced system that combines simula-

tor and live arc welding.

“Our interest in LiveArc was to use it

as a training tool to minimize weld de-

fects—to make sure that our employees

have the fundamental skills to produce

quality welds to build a quality product,”

said Mann. “The welders using LiveArc

get instant feedback and can under-

stand from the visuals [on the computer

screen] what they need to correct. The

biggest attraction for us is that there is

a simulation mode in which they can go

through and run it without welding first.”

ALMACO has seen a significant

reduction in the amount of time it takes

to transition a welding operator from

training to production, due to the instant

feedback from the LiveArc system. “Hav-

ing that instant feedback shortens that

learning curve tremendously, because

they can make the weld and then they

can review their performance and make

those adjustments, versus running six or

eight welds and then finding an instruc-

tor to have them critique it,” Mann said.

The LiveArc system also allows train-

ers to focus on other tasks, or to help a

larger pool of new hires in the transition to

the production floor.

“As training technicians, we’re able

to enhance our training system and it

doesn’t require as much time from us in-

teracting with the new employees,” said

Jeff Pratt, ALMACO training technician.

“That allows us to get some other things

done that are our responsibility.”

The system is also a good tool for

speeding up the hiring process, since

ALMACO uses it to gage the level of

welding fundamentals that potential

candidates have.

Faster welding operator training—

and the fact that they are using fewer

coupons during the process—has also saved ALMACO in

training costs. The simulation mode allows the welding op-

erator to simulate the weld and make the necessary adjust-

ments before completing real welds.

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“We have been able to reduce our training costs [for cou-

pons] due to the fact that we can run it in simulation mode,”

Pratt said. “The other plus is that LiveArc allows you to stack

coupons on top of each other and continue to use that

material more than you would on other

training systems.”

The cost savings have also carried

over into the production area, where

ALMACO is seeing less rework due to

the LiveArc training. “We have seen a

reduction in rework with weld defects,

which has led us to our primary focus on

the other skillsets that are required once

they transition from training to produc-

tion, such as their layout and fabrication,”

Mann said.

ALMACO has found that the system

offers an intuitive platform that requires

minimal orientation before training begins,

so new hires take to the system quickly.

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Continued on P130

At ALMACO, Jeff Pratt, training tech; Dustin Johns, welder/fabricator; and Chris

Mann, senior manager (left to right) have all seen improvements in welding training

with the new Miller Electric LiveArc system.


“It’s easy and quick for the new hires to learn,” Mann said.

“The welding instructor runs them through and identifies the

functions of the gun, how that’s integrated into the system and

the feedback it’s giving them, and then basically walks away.”

The system provides step-by-step instructions, allowing

trainees to move from one assignment to the next. That’s

important for ALMACO, which draws welding operators with

diverse levels of training and experience.

“It basically tells you everything that

you’re doing right and wrong,” said

Dustin Johns, an ALMACO welder/

fabricator. “It covers the fundamentals

of keeping your lead angle, work angle,

contact to work distance, travel angle,

travel speed. It tells you exactly what

you’re doing.”

The system includes preset training

programs, but can also be customized

with new programs.

The LiveArc system provides a good

opportunity to collect data and to cus-

tomize the training program. ALMACO is

able to use data collected by the LiveArc

system to see how a welding operator’s

performance improves throughout the

training process. “We have already seen

improvements on weld quality as a result

of that,” Mann said.

“Our hope for the future is to get all

current employees entered in there and

use it as a training tool,” Pratt said.

ALMACO also customizes the

LiveArc system for the company’s spe-

cific applications and needs, so welding

operators learn the fundamentals to

apply to the company’s products.

ALMACO can input thickness of wire

and material, travel speed, contact tip

to work distance, joint positioning and

other factors to its training program.

“The great thing about LiveArc is

we have the ability to customize our

training to our needs,” Mann said.

“Regardless of job description, we can

cover every aspect of what we need.

Our line of work is custom. It’s not all

fixtures; it’s not all benchtop work. We

do a lot of out-of-position welding.

Some of the most frequent fundamen-

tal errors that we have are in the out-

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SHOP SOLUTIONSContinued from P64

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of-position welding, so that was very important for us to be able to get accurate

feedback to correct those.”

“The training from LiveArc is very beneficial to employees,” said welder/fabrica-

tor Johns. “It teaches them how to weld up to ALMACO standards.”

For more from Miller Electric Mfg. Co., go to www.millerwelds.com, or phone

920-734-9821.

Continued from P53

Presetting System SavesDie-Maker Time, Money

H. Beck Machinery Ltd. (Windsor, ON, Canada) specializes in high-accuracy,

large-scale CNC custom machining using 10 large machines from boring

mills to a six-axis Droop + Rein mill and a five-axis Fidia machining center. The

company machines automotive stamping dies complete from roughing to finishing.

“With our wide range of large capacity milling machines, we can handle a variety

of different machining applications, and we are always eager to meet new chal-

lenges,” said General Manager Markus Lewandowski.

Beck Machinery’s specialized jobs include Class A stamping dies for the auto-

motive OEM and Tier One suppliers. The parts are very large—weighing up to 20

tons—and are for pressing an entire bodyside for a vehicle. They are very costly to

cast and then to machine, so mistakes in machining must be avoided.

It typically requires more than two weeks on two shifts for roughing and finish-

ing, so it is essential to have correctly set tools in three dimensions for every

machine to run reliably untended. The finishing machines—the Fidia and Droop +

Rein—usually run 24/7 with spindle speeds up to 24,000 rpm. The Fidia has run

almost 24/7 since 2009. Machines are inspected every year and laser calibrated in

each axis.

Markus Lewandowski with the Zoller smile vision-based tool presetter that can

measure every type of drilling, turning, and milling tool.



The tooling cost, tool adjustment time, and potential vari-

ability between tools and inserts used to machine the dies, led

Lewandowski to seek a better way of managing the tools. On

a trip to Germany, he visited Zoller at a trade show. After further

investigation, the company ultimately invested in a Zoller smile

CNC presetter, a tool management system, and a Zoller Tool Or-

ganizer for storing tool inventory from Zoller Inc. (Ann Arbor, MI).

It was an important step for the company. The new tool

management system helped reduce machining time, contrib-

uted to improved die quality, resulted in tool cost savings, and

reduced tool design time in the CAM room. The tool manage-

ment system includes storage and interface to the ToolOrga-

nizer, NC program management, management of measuring

devices, fixture management, tool usage statistics, stock

recording and ordering directly from the presetting department.

“Today, due to optimized tool-change, presetting, and

storage procedures, we have gained 1500 hours of machine

time per year,” Lewandowski said. “Laser-checking the

tool length on-machine did not permit running all weekend

untended. The machine would stop if it detected an incor-

rect tool point location before machining. Operators would

have to touch off the Z height with the laser checker in the

machines. A couple of hours of pre-lasering tool lengths and

adjusting was typical before we could begin machining.”

H. Beck can now manage its full complement of tools

from the office—CNC machines, SupplyBay Vending Ma-

chines, Zoller ToolOrganizers—or directly at the presetting

and measuring machine and enjoy central data storage in the

Zoller system. H. Beck takes advantage of stored tool data

and DIN 4000 article characteristic information to optimize in-

ventory cost control as well as tool production. Management

can regularly see tool ordering and cost reports.

One of the keys for H. Beck is the tool storage manage-

ment module of the system that allows it to manage tool

assemblies and tool components, and keep accessory

inventories up-to-date. The storage location management

in the warehouse includes a 3D design kit which allows the

company to display current stock three-dimensionally, easily

and quickly and assign items to a virtual bin location.

Since H. Beck has installed the Zoller system, it fully

prepares each tool for the job before it starts, avoiding mis-

steps in production and operator time wasted looking for the

correctly built tool for the job.

“With the Zoller system we identify every tool with a tag,”

Lewandowski said. “Although the machines have a laser

for tool length adjustment, using it makes for a longer tool

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measuring cycle at the machine. Presetting on the Zoller, we

are now within 0.005 mm on every tool without wasting time

on-machine for setting tools.

“Previously, over the machining of a typical die we would

have used up to several hours of machine

time adjusting tools,” Lewandowski

said. “The five-axis machine required

tool length adjustment for every tool and

insert change to identify Z. This was done

on-machine by feel. Using the Zoller

system, on the other hand, has improved

the quality of the dies because the Zoller

can confirm that the tools are adjusted

dead-on, tool to tool.”

For their application, serving an entire

shop, H. Beck chose the smile 600

universal CNC tool presetter. The Zoller

smile at H. Beck provides a measuring

range of 600 mm in Z, 300 mm in X,

and 600-mm tool diameter with spindle

supports for HSK63 and steep taper 50.

The Zoller smile tool presetting and

measuring machine is easy to operate,

equipped with all required standard mea-

suring functions, and is designed specifi-

cally for measuring tools for manufactu-

ring production. The vision-based tool

presetter and measuring machine can

measure every type of drilling, turning and

milling tool. Its operation is easily learned.

Zoller high-performance image

processing technology helps speed tool

measuring in the H. Beck tool presetting

room. Ideal for shop-floor operation, smi-

le offers an ergonomic, functional, modu-

lar design of robust proven components

matched with upgradeable software.

“Every tool is 3D-scanned and that

information is output in our machining

simulation data,” Lewandowski said.

“Since every tool has a tool number and

known characteristics, we can load the

tool in the part process with full con-

fidence that the tool is precisely what

is needed to machine the dies. This

process means that in the CAM room

we save 200 hours of design time each year by scanning the

tools compared to designing them.”

For more information from Zoller Inc., go to www.zoller-

usa.com, or phone 734-332-4851.

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SHOP SOLUTIONS s Problem Solving on the ShoP Floor SOLUTIONS s Problem Solving on the ShoP Floor Kevin Hjelmgren (left) and Gary Warlow wote progams using GibbsCAM macros to …