Tebis at the "HSC finishing in die manufacturing" workshop
At the "HSC finishing in die manufacturing" in Borken on November 4 and 5, 2015, hosted by FOOKE GmbH, MMC Hitachi Tool GmbH and Tebis AG, nearly 40 participants worked intensively to address the question of how best to meet the special challenges in die manufacturing. The quintessence of the event: Modern HSC milling strategies enable productive machining of high-strength materials. An essential prerequisite for this is the exact matching of highly dynamic machine centers, optimum CAD/CAM solutions and powerful tools.
The specialists from Tebis AG held three presentations covering different aspects of CAD/CAM solutions.
In his first lecture, "Meeting the challenges of market developments with the right settings," Martin Vortmann, Cooperation Manager presented the current situation in die and mold manufacturing. Current developments do not appear especially promising at first glance: Prices for dies are decreasing faster than manufacturing costs, competition is becoming stiffer, dies more complex and deadlines tighter, and the situation is further exacerbated by a shortage of qualified personnel. However, companies are still working significantly more efficiently despite these challenges and are securing their long-term competitive edge using the complete process-oriented solutions from Tebis. Vortmann presented approaches to practical solutions in his second lecture, "Fully exploiting all potential." This presentation specifically addressed shorter processing times, optimum machine utilization, fast and reliable NC programming, high flexibility and fast integration of new personnel.
In his presentation, "Active surface preparation and reducing tryout expenditure," product manager Stephan Galozy contributed a sore point to the agenda: Tryout is currently still a highly laborious manual process for most die manufacturers with the clear disadvantage that manual reworking takes far too long. Galozy illustrated how die tryout time can be significantly reduced with the end-to-end Tebis process comprising the active surface, NC programming and tryout. Concrete numbers speak for themselves: For example, in a side panel drawing die, spotting time can be reduced by roughly 60 hours per side, corresponding to a cost savings of €10,000 per die. This is how the Tebis active surface process works.
The event hosted by the three partners was crowned by the machining of an actual workpiece on an Endura 704Linear compact gantry milling machine using special high-speed cutting tools from Hitachi. This example combined classic and simultaneous strategies to exactly match the workpiece. Pre-finishing focused on the short machining time, while the primary emphasis in finishing was on the high quality of the surfaces.