PJK Peter Josef Klein Feinmechanik in St. Augustin near Cologne has enjoyed sustained success by focusing on high-end CNC machining. Founded in 1983 and managed by the second generation of Peter and Julian Klein, the company concentrates on the complete machining of sophisticated components for medical technology and biotechnology, food machine construction and general mechanical engineering. A wide variety of materials are processed - from engineering plastics, aluminum, steel and stainless steel to Inconel and titanium. And high-performance CAD/CAM tools are used, whereby the Solidworks/SolidCAM platform has formed a central basis for many years.

A look at the "store floor" may be surprising at first glance. Other CNC machining service providers are proud of their diverse machine park. But despite the variety of materials and components, PJK deliberately does not rely on "diversity" when it comes to machines. Peter Klein: "We only use one type of machine for all milling tasks: DMG Mori DMU 60 eVo machining centers. These machines are very flexible. And what they can't produce, we don't produce."

Flexible machining centers

Flexibility is further increased by the fact that all machining centers can be loaded both automatically and manually. For example, PJK can process small quantities during the day and larger series during the "unmanned" night shift. The advantage of this concept is obvious. Peter Klein: "We are unbeatably flexible and manufacture very efficiently because machine utilization is consistently high. They also enable us to meet the highest standards of precision. We can also guarantee short delivery times - something our customers appreciate."

PJK also relies on a standardized and consistent solution for programming and simulation. Julian Klein: "We have been working on the Solidworks/SolidCAM platform for many years - both for turning and milling simpler components and for five-axis machining of complex components."

Another principle: programming is always done offline. As Julian Klein describes it, this offers three advantages: "We can guarantee a very high level of quality because we have really very good programmers. The simulation ensures that we can produce series parts quickly and without errors. Because every tool is mapped in the simulation, we can be sure that we can produce 'live' right from the start without any problems. And thirdly, the machines are better utilized when programming is done offline."

Continuous further development

PJK has also been working with DPS Software for more than ten years to continuously develop the CAD/CAM platform in-house. Ulrich Klein, CAM Account Manager at the DPS branch in Dortmund: "The regular discussions with PJK are always exciting and productive. The company is very agile, well informed and always uses new SolidCAM modules and technologically up-to-date postprocessors - with the aim of always being at the forefront of technology and gaining competitive advantages."

One of the SolidCAM tools that PJK uses intensively is iMachining. This software optimizes the tool engagement angle and the cutting speed over the entire machining process. The result: the machines mill more efficiently and therefore much faster. At the same time, tool life is increased. Julian Klein: "Our programmers decide on a case-by-case basis whether to use this tool. For prismatic 2D components, it can make sense depending on the component contour, but it definitely makes sense for complex 3D parts. Here, optimized milling speeds up the machining time tremendously."

With the combination of universal (and uniform) CNC machining centers and the Solidworks/SolidCAM platform, PJK has a very good basis for highly efficient precision machining. The management agrees. Julian Klein: "We are completely satisfied. We can also machine very complex parts with high precision - with fits down to the µm range - in a single clamping operation. The continuous flow of information based on Solidworks/SolidCAM makes a key contribution to this, as does the efficient workflow with high-quality and standardized machines."

Learning calculation software

On this basis, PJK will continue to optimize processes at machine and software level. Recently, for example, the company introduced "learning" calculation software. Peter Klein: "We enter the component data and, once the order has been completed, the actual processing times, which the system takes into account for all subsequent projects. This makes the calculations more and more precise. It works very well." The expansion of (naturally flexible) automation and the use of further SolidCAM modules are also currently on the agenda.