Staying Competitive

CAD/CAM software aids racing engine block shop

Located just 23 miles from Detroit in Warren, Mich., Schwartz Machine Co. is a prototype company serving the automotive, marine, and heavy equipment markets. Customers such as Caterpillar, Ford, General Motors, Mercury Marine, and NASCAR racing rely on Schwartz to turn their cutting-edge designs into functional products. Founded in 1952, Schwartz Machine specializes in the precision machining of racing blocks, cylinder heads, and mobility components, as well as fixture design. To meet the needs of its customers, the company works with a wide range of materials. In the 44,000-sq-ft shop, titanium, zirconium, magnesium, aluminum-silicon, compacted graphite iron (CGI), and a host of other materials are machined on a series of vertical and horizontal CNC machining centers, CNC turning centers, and conventional machines.

A longtime, reliable source for cylinder heads and engine blocks in NASCAR racing, Schwartz is adding electric vehicle components such as inverters, gears, and battery boxes to its growing product lineup.

"It's interesting work," said Frank Balsamo, Schwartz Machine manufacturing manager. "We do all the Chevy NASCAR racing blocks and heads, so if you’re watching a NASCAR race and a Chevy is winning, we did something to help them win. It is exciting."

Since its founding, Schwartz Machine has grown in size—and in machining capabilities. In 1975, management purchased the shop's first piece of CNC equipment and continued to take on increasingly complex jobs. Balsamo remembers when the company purchased its first seats of Mastercam CAD/CAM software (CNC Software, Inc., Tolland, Conn.) in 1997, a move that paved the way for 3D work and an expanded customer base.

"Our company went with Mastercam," he said. "We were then able to take on new work. We made a valve cover out of solid aluminum for one of the racing teams and it turned out great. That really opened the doors for all kinds of jobs. Mastercam brought us from 2D and drilling to 3D and billet work. We use it for everything. We find a way to machine jobs, no matter what."

Schwartz Machine's successes with CAD/CAM software eventually led it to transition into multiaxis machining. The technology simplifies programming, required motions, and fixturing for complex parts. The results? Improved surface finishes, elimination of multiple setups, and increased accuracy.

"If I’ve got a 5-axis machine and I have to get a hole way down in somewhere, I can rotate the part in Mastercam to get me there," Balsamo said.

Because Schwartz machines prototypes, its employees design and machine their own fixtures and tools for a range of parts, including complex intake manifolds. Programmers use Mastercam Design to create special step endmills, drills, and other tools. The computer-aided design solution's suite of CAD tools simplifies the creation of even the most complex parts. Features like direct modeling, file import functionality, and model prep all contribute to production efficiency.

Schwartz’ fixture-building process begins with importing a model into Mastercam. A fixture is designed to hold the part, while clamps are imported into the dimensional fixture through the software. In addition to fixtures, the company designs and builds its own tooling.

"We give our jig bore operator the plate and dimensions and we order all the clamps we need, then we’re done," said Balsamo. "With tooling, I can project a line down a stepped hole on a part and flip it sideways, dimension it, and send it to a cutter grinder to cut a nice carbide tool to match the hole and the part."

Balsamo estimates that each year, Schwartz designs and builds 200 to 300 tools, including step drills, endmills, and reamers, all designed with CAD/CAM software. Creating new tooling can be challenging, but the software enables the Schwartz team to keep up with demand. Understanding and maximizing the software's capabilities—namely Dynamic Motion technology—are key to increased production and reduced cycle times.

"If you’re using Mastercam to run a tool at 5 inches per minute at 1,000 RPM on aluminum, you’re not using your time efficiently," said Balsamo. "Mastercam has Dynamic Milling that you can run at 20,000 RPM at 200 inches per minute. You can get the part done in one-tenth of the time."

Dynamic Motion technology makes it easy to cut hard material, which is important for Schwartz Machine because its jobs require such a broad range of materials. Dynamic Motion produces consistent chip thickness, ensuring even heat distribution and load throughout the cut. Material surface hardness is eliminated along with the risk of tool breakage. No matter the material, a machinist can never overload the tool, which means results are predictable and consistent. New and old machines alike perform better and last longer, enabling extended tool life. This is good news for a shop with more than a dozen CNC machines.

"Over the years, I’ve used a lot of Dynamic Milling," said Balsamo. "The tools last much longer and the older machines are holding up. If you take a deep depth of cut and a shallow cut sideways and fast, it's amazing how long the cutters will last. Rather than burying a cutter and trying to cut a lot of metal all at once, you do it quick in short passes and the part turns out great."

Reflecting upon the impact of CNC machining and CAD/CAM on Schwartz Machine, Balsamo recalled when the company had one person running a manual machine to produce an engine block prototype. It took the machinist three weeks to complete the part. To remain competitive today, manufacturers must produce high-quality parts within the shortest possible cycle times.

Using the CAD/CAM software's extensive toolpath options, a Schwartz machinist can now machine an engine block in one or two days compared with three weeks or more using traditional methods. Improved machining capabilities, along with software support, have made an important difference at Schwartz.

With more than two decades of Mastercam experience, Balsamo knows his way around the software. But he admits that when Schwartz purchased its first seats, he leaned on the expertise of Mastercam-reseller Axsys Inc., Wixom, Mich., for technical support. That expertise is just as important today as it was then. The team continues to collaborate with Schwartz programmers on necessary updates, training, and process issues. Phone calls, visits, and virtual consultations are effective customer-support tools.

"If we’re having a problem with an existing program, we can use Zip2Go and send everything to Axsys," said Balsamo. "Our rep Kris Richardson opens it up and sees exactly what we’re doing on a part, figures out some way to fix it, then sends it back to us."

Mastercam's handy Zip2Go utility gathers part data into a .Z2G file and attaches the file to an email. Found in the Help menu, this simple tool zips up all active project information that is relevant to a customer question or issue. When he first started working with Mastercam in 1997, Balsamo had to call Axsys several times per week.

"They probably got tired of hearing from me. However, they always gave me answers and came out when it was necessary," he said. "Today, e-Mastercam has forums. I can go on there, type out a question, and get twenty answers from around the world within ten minutes."

Software support is vital to customers, especially to small companies such as Schwartz. Several years ago, a programmer was having issues machining a part on a newly purchased machine. An Axsys representative drove to the shop, spent the day with the programmer, and resolved the issue.

"Although the machine was not a true 5-axis, Axsys found a solution to make it work," said Balsamo. "As a result, we were able to do 5-axis machining on a billet part. There may be other software capable of machining that part, however, I don't think any other company would offer the support that Schwartz Machine has had from Mastercam and Axsys Inc."

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