How a Precision Machine Shop Boosted CNC Productivity with CAM and Multi-Axis Machining
Ketchie Inc., a third-generation precision machine shop in Concord, N.C., has evolved from a textile job shop into a high-tech CNC machining powerhouse. Serving industries from rail to agriculture, the company accelerated its growth trajectory in 2021 by integrating Mastercam CAD/CAM software (CNC Software, LLC, Tolland, Conn.) with its existing Mazak equipment.
This move has enabled Ketchie to optimize toolpaths, embrace multi-axis machining and achieve significant reductions in cycle time and tooling costs—positioning the shop to meet its ambitious 15% annual growth goal.
According to Jim Thorpe, quality assurance manager, Ketchie is constantly challenged to be more competitive. Machine shops prevail in Concord as it is home to Charlotte Motor Speedway and a host of racing companies, as well as textile and agricultural manufacturers.
Since it began CNC machining in 1980, Ketchie has used Mazak (Florence, Ky.) CNC mills and lathes run exclusively by the Mazatrol conversational programming mode. When searching for a new CAD/CAM system, the Ketchie team sought seamless integration with its existing systems.
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“We didn’t want to go back and rewrite every program, but with Mastercam and Mazatrol, we blend it,” said Thorpe. “We use EIA (Electronic Industries Association G-Code) programming mixed in with Mazatrol. If we find an outdated toolpath or something that we’d like to replace with Mastercam—area mill, rough mill, anything that will create a faster path through the materials—we’ll cut that part of the program from Mazatrol and insert the Mastercam EIA G-code program.
“We don’t have to start over with all of our programs. We’re able to patch and play until we get to the point where we get everything done through Mastercam offline.”
Rolling in Sub Spindle Tech
To meet its growth goal of 15% each year, the Ketchie team knew that it would be necessary to expand its high-speed machining toolpaths and multi-axis machining efforts. In addition to investing in CAD/CAM software to support future growth, Ketchie purchased a dual spindle lathe. Employees had extensive experience with Mastercam and Mazak, but not all had experience with sub spindle technology.
Ketchie looked to its Mastercam reseller, Barefoot CNC (Morganton, N.C.) for help. The Barefoot team worked with Ketchie to create programs offline that the manufacturer could not create at the machine control. By creating 3D milling paths to rough and finish tapers on some of the company’s highest part runs, an entire operation and set up were eliminated.
The addition of multi-axis machining is already opening doors for Ketchie. As the company looks to the future, additional applications for 5-axis machining are being explored.
Technology upgrades are paying off as Ketchie explores machining strategies. For example, one part for the rail industry requires a 4-in. tapered bore. In the original manufacturing process, the parts were roughed by a series of circle interpolations; more than 400 total cuts were required to get through the part.
After purchasing Mastercam, Thorpe was able to create 3D toolpaths to rough and finish the part. The new machining strategy eliminated an entire machine, machine setup and operation. Ketchie saved 20% of machine cycle time per part by making this change. Originally, the part was roughed on the mill then finished on the lathe. By using Mastercam and 3D toolpaths, cycle time was reduced.
An Added Bonus: Reduced Tooling Costs
Besides cutting production time, Ketchie is saving money on tooling. Before employing modern CAM toolpaths, inserts and tools were frequently replaced, which incurred added production time and costs.
“We were machining six pieces on the inserts before we had to change them. With the 3D toolpath, we can cut up to 15 pieces per insert now,” said Thorpe.
On the lathe, with the use of the sub spindle and Mastercam, Ketchie has had multiple instances in which the CAD/CAM software allowed creation of new toolpaths that led to elimination of the mill operation. Parts are run on the lathe alone. This change proved advantageous because a machinist can now set up a part and run a program after hours. The new machining strategy helped Ketchie perform more lights-out machining, resulting in reduced labor costs and increased production capacity.
One part in particular is manufactured for the fluid motion control industry and required two operations on the lathe before it moved to the mill for the machining of six slots. Made from 4140 steel, the part had 1-in.-wide by 6-in.-deep slots cut by an ISCAR insert cutter.
Now, with the use of Mastercam Multiaxis, Ketchie can produce the part from start to finish on the lathe. Multi-axis allows complete control over cut pattern, tool axis control and collision avoidance. By eliminating the mill operation, machine time for the part was reduced and the shop’s overall production schedule is more efficient since that machine is now open for other jobs.
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“For my entire career, I’ve been told that one day we’d be able to throw a drawing into a machine and the machine would program a part,” said Thorpe. “When I saw that I could put a PDF into Mastercam and use it as geometry, I said, ‘Finally! It’s happening. I always knew it.’”
No matter what size the business is, investing in employees and technology is key to long-term success. “We shine a pretty bright light on the importance of manufacturing and supply chain in our country,” said Courtney Silver, president and owner of Ketchie Inc. “For small manufacturers, it is a big responsibility to be the most competitive you can be, which means keeping up with machining technology and constantly investing in your people, processes, and equipment. There are situations in which we can beat offshore pricing with automation, robotics and with unattended machining rates.”
By diversifying its customer base, including earning contracts from the U.S. Department of Defense, Ketchie Inc. is on track to reach its 15% growth rate.
