When manufacturers evaluate new capital expenditures based on future growth opportunity, frequently the process involves comparing rebuilding, remanufacturing, and upgrading of existing equipment vs buying new. This is exactly the decision-making process that Atlanta, GA-based McClain International went through when its CMM measuring and production capabilities needed to be improved.
“We’ve been living with an older manual-operated Brown & Sharpe Validator and a newer Mitutoyo Bright CMM for a long time,” says W.C. (Guppy) Gladstone, McClain’s quality manager for over 18 years. “Back in 1997-98 we upgraded the Brown & Sharpe with a Metronics QC5000 reporting system and have added the Mitutoyo unit to handle larger air seals. One CMM is used in the in-process inspection area and the other at the back end of the manufacturing process for final inspection. With all the advancements in CMM technology, we were well aware that we could improve the speed and ease of inspecting and measuring our turbine air seal parts with better equipment.”
The Search for a Solution
Initially, Gladstone researched possible machine, controls, probes, and software upgrades through Internet searches. In the process, he discovered Xspect Solutions, a company that not only had extensive rebuilding and remanufacturing experience, but also was the North American sales and service organization for new Wenzel CMMs. (McClain's new Wenzel LH 16.12.8, shown here, is located on the manufacturing floor to enhance the flow of turbine air seals through the department; note wireless teach pendant on the table, foreground, and probe rack mounted to the granite table.)
“Having spent a career in quality management, I’ve had a good deal of experience with different CMMs and developed personal perceptions and opinions about certain machines and their operating software,” he says. “However, the accuracy and ruggedness of Wenzel CMMs I have always admired, particularly their continued use of granite construction. What I didn’t realize . . . is the fact that the equipment is very affordable, even for a company of our moderate size.”
Ultimately, the decision was made to purchase a new larger Wenzel LH 16.12.8 CMM equipped with OpenDMIS™ software to replace the older machine, and to have Xspect Solutions provide a complete CNC controller upgrade package with OpenDMIS™ software for the Mitutoyo.
Benefits of Standardizing
“Having common software on each machine allows common programs to be used for in-process as well as final inspection,” Gladstone explains. “One engineer and one member of quality management have attended the OpenDMIS™ training sessions at Xspect Solutions in Wixom, MI and have quickly been able to absorb the basic software concepts and are now programming with OpenDMIS™.
“There are some additional features on the new Wenzel machine that really help enhance the measuring operation,” Gladstone adds. “Because both the ID and OD of the turbine air seal rings are inspected, we needed the speed and accuracy of a motorized probe head. As a result, the machine is equipped with a Renishaw PH10M/TP20 probe that allows inspection at optimum angles and up to 720 repeatable positions. For inspecting the various diameter turbine air seals for roundness we have permanently mounted 1-in. square steel bars to the granite plate of the CMM at right angles to create a standard nesting fixture for the air seals. This simplifies the part programming because each part starts with the same nesting coordinates.”
The Wenzel WPC 2030 universal CMM controller combines the latest CNC technology with the integration of all Renishaw heads with touch trigger probes. Also, the HT400RC wireless teach pendant with long charging cable eliminates the tedious keyboard interaction typical of conventional CMM teach pendants.
“With the wireless joystick, I basically have everything I need right in my hand. You can walk around the machine and get close to the work without having to determine the orientation of the pendant control because it does that for you. Also, the Wenzel machine is equipped with a convenient and time-saving probe change rack, for use with the interchangeable TP20 magnetic stylus probes, that mounts right on the granite table,” Gladstone concludes.
The McClain International Wenzel LH 16.12.8 has a measuring range of 1,200 mm/47 in. (X) x 1,600 mm/62 in. (Y) x 800 mm/32 in. mm (Z). Large Wenzel CMM machines like the LH 16.12.8 have a self-stabilizing design, with integrated pneumatic vibration dampeners that eliminate the need for an isolated foundation. With the X bridge and Z ram manufactured of granite, identical thermal behavior can be predicted for all axes.
The OpenDMIS™ software provided to McClain International is taking the guesswork out of CMM programming by providing the ability to seamlessly integrate the CAD data of the turbine seal rings with the CMM programming and measurement process, providing McClain with a high level of power, precision, and productivity at the single click of the mouse. Drag-and-drop features from the database area into the adjacent programming window automatically generate the underlying DMIS 5.0 code, together with probe and alignment definitions.
Complex turbine air seal CMM programs can be created in a few minutes and simulated, utilizing the powerful simulation and collision avoidance tools standard in OpenDMIS™. There are no pop-up windows in OpenDMIS™. The product incorporates dynamic sensitive tool bars, action icons and context-sensitive work areas. The graphics view port remains freely visible at all times, maximizing operating efficiency. There are no windows to close and no cascading windows, and typical screen crowding is eliminated, as is annoying drill-down functionality.
