Unlock smart manufacturing for the automotive industry

In the dynamic realm of automotive manufacturing, innovation is non-negotiable. Amidst this imperative, virtual Computer Numerical Control (CNC) software emerges as a game-changer, revolutionizing traditional processes. This white paper explores the transformative impact of virtual CNC software on automotive manufacturing, highlighting its role in enhancing efficiency, precision, and agility.

Virtual CNC software enables automotive manufacturers to simulate and optimize machining processes before physical production commences. By digitally modeling components and simulating machining operations, errors are minimized, lead times reduced, and resource utilization optimized, bolstering productivity and cost-effectiveness. This technology fosters innovation in product design and customization. With rapid prototyping and iterative design capabilities, manufacturers can explore new concepts swiftly.

Additionally, through realistic simulations of machining operations, operators and engineers can enhance their skills in a safe, controlled environment, eliminating the need for costly physical prototypes or machine time.

As the automotive industry evolves, integrating virtual CNC software becomes a strategic imperative for manufacturers. By embracing this technology, companies can unlock new avenues for growth, efficiency, and innovation.

Vericut’s commitment

The automotive industry has been through major changes and those that have survived have been prepared and adaptable. The more recent shift towards electric vehicles, plus the future outlook on more autonomous vehicles, come with great challenges for the industry.

Alongside other priorities, the goal of energy-efficient manufacturing – reducing energy consumption and increasing sustainability – is at the forefront for all manufacturing businesses. In order to rise to the challenges, automotive manufacturers need to redistribute their budgets quickly and in a targeted manner. Research and development need to focus on software and on manufacturing feasibility. The software needs to enhance the performance of the products while keeping costs down.

Focusing primarily on processes, rather than on individual machines, systems, or functions. Even in a downturn scenario, fast, decisive action on investments in the next technological generation for better workflows must not be taken for granted.

Of course, the possibilities of smart alternatives in automotive manufacturing are based primarily on stringent digitization. It is not for nothing that NC simulation is considered a lighthouse project and early mover among the digital game changers as the interface between CAM programming, work preparation, and the shopfloor.

Manufacturing simulation of the NC data, i.e., the machine code, addresses the really important fields of action in metal-cutting manufacturing: safe prove-outs of complex clamping situations, manufacturing without scrap, machining without machine collisions, increasing tool life, faster NC programs with reduced machining times and improved part quality.

The automotive industry puts high demands on machining.

The drive for high quality and high volume will remain key to the industry, and cycle time – cost, seconds and pennies – will always be a concern. The move towards hybrid vehicles continues to rapidly pick up pace and plug-in hybrids are becoming even more popular. The future is battery electric or fuel-cell electric vehicles, referred to as NEV – New Electric Vehicles..

These changes in the automotive industry require new types of components, including electric motor housings, new types of gear housings, new examples of covers and all accessories related to E-mobility. There will be increased demand for retooling, new tooling and processes to produce these components. 

Manufacturers face a whole series of problems that intersect between CNC programming, planning, and production. Below is a summary of these challenges:

1. Supply Chain Disruptions: 

Potential disruptions in the supply chain, such as those caused by geopolitical tensions or natural disasters, can lead to price fluctuation and shortages. Anticipating these disruptions can mean successfully mitigating potentially fragile manufacturing situations and maintaining stable operations.

Tip: Beyond the typical corporate activities to counter impending supply problems, companies must achieve new levels of internal efficiency to address the need for materials and energy. Focus is on planning production efficiently from the start, and digital solutions that combine both quality assurance with autonomous production control will increase the resource efficiency of manufacturing processes.

2. Technological Advancement

With the rapid advancement in technologies like electric vehicles and autonomous driving systems, manufacturing processes must remain adaptable and flexible to incorporate these changes quickly and efficiently. Investments in new initiatives and technology adoption within manufacturing facilities.

Tip: Changes in the automotive industry will require new types of components, tooling and processes. High volume will remain key to the industry, and any mistakes can be costly. Consider the production environment – the machines, their automation, the required floor space, raw materials and invested capital – and the initial information required for accurate process planning – machining operations, required tools, the cycle time, production rate and requirements.

3. Sustainability & Environmental Regulations:

Politically intended and socially approved, sustainability is an obvious and logical goal. Companies often see it as their duty to implement the principle and practice of sustainability. If done correctly, specific measures can be positioned within manufacturing processes and product design to reduce environmental impact and to comply with regulatory standards.

Tip: To minimize the CO2 footprint, for example, companies will want to use raw materials and energy efficiently. Quickly digitizing defined manufacturing segments is a good example, reducing the material used, energy spent, and time wasted on manual prove-outs.  

Safely testing and producing any parts in a virtual environment often negates the need to physically test run, or prove-out, a part prior to production, which removes the chances of scrapping (wasting) raw material to generate an erroneous part, along with chance that the NC program might contain errors that could cause the machine tool to crash and become damaged.

Optimizing the NC code to produce a more efficient program results in manufacturing cycle time savings of between 10% and 40%, depending upon the raw material and complexity of the parts. The savings from wasted time and power consumed are significant.

4. Quality control & Product Safety:

Maintaining product quality and safety is crucial in the automotive industry. Having quality control measures and protocols in place throughout the manufacturing process to identify defects or issues early on is essential to production schedules, cost control and customer satisfaction.

Tip: Every step in the process – engineering, design, CAM programming and machining – should be inspected, verified and optimized. Simulation and verification technology ensures programs are error free and all operations work together as intended, and optimization ensures the whole process is operating as efficiently as possible to save time and money.

5. Workforce Skills & Training:

Continuous development of the workforce and improving their skills will increase productivity, improve the quality of work, and reduce faults, waste or customer complaints. As industry and manufacturing technologies evolve, so too should the workforce.

Tip: There is no denying that skilled machinists are hard to come by. With a large percentage of the current workforce of NC programmers and machinists getting ready to retire and a shortage of newly qualified engineering talent, finding people to work in this industry and fill the void is becoming increasingly more difficult.

Software can provide a large amount of data and information that can be used to improve the manufacturing workflow and free up a skilled machinist’s time.

Engineering companies are now facing the challenge of meeting increased demands and staying competitive with fewer programmers and machinists. Working smarter with software reduces the need to fill all those voids.

CNC simulation software can verify a part, simulate the machining and optimize the NC code before any real machining has started. Therefore, making unattended or lights out machining, and the ability to operate with less machinists, a reality.