Nearly 80 participants at the "Three partners for efficient manufacturing" workshop
Software, tools and machines as well as empirical manufacturing knowledge determine the quality of a component. When all of the influencing factors are precisely coordinated, the most modern die technology, highly dynamic machine concepts and powerful process modules yield an optimal milling result – the nearly 80 participants at the joint workshop conducted by the three partners Aura, Röders and Tebis on April 27th and 28th in Soltau had the opportunity themselves to experience this live.
Jürgen Röders, managing director of Röders GmbH, welcomed the guests on both days. Then the presentations began. Each of the three companies reported from different perspectives on the key factors affecting good milling quality. The participants continued the lively discussions during the breaks, proving just how important these topics are in die and mold manufacturing.
Software, tools and machines have to be perfectly integrated
In his presentation "Efficient manufacturing", Martin Vortmann, Cooperation Manager at Tebis AG, elaborated solutions for shortening throughput times, optimizing machine utilization and reducing programming times. With process libraries and templates technology, Tebis provides the basis for reliable, automated and simultaneously flexible processes. Tebis experts help to set up the libraries for the best performance. Just one example: A clearly structured tool library ensures that a large number of individual tools can be replaced with standard tools and only a small number of specialty tools.
Vortmann also presented several specific Tebis functions, the advantages of which are immediately apparent in manufacturing. Among these are the new roughing strategies for adaptive roughing and integrated re-roughing, which have been available since Tebis Version 4.0 Release 2. Geometries with steep cavities can be very efficiently machined with simultaneous high tool service life using the new strategies and HPC cutters – time savings of up to 60 are possible, even for hard materials. Tebis also scores with a high-precision contact geometry, with a one-to-one correspondence of the contour of the virtual tool with that of the actual tool. Contact with the material and residual stock can therefore always be exactly determined.
Dr. Oliver Gossel is the sales manager for HSC machines at Röders, which has specialized in mechanical engineering for high-precision HSC milling and grinding machines in one of its three business sectors. In his presentation "Optimal machining quality through perfectly matched technology" he very clearly explained again how the strengths of the high-performance milling machines from Röders can best come into play when the NC programs and postprocessors "fit" the machine. In a nutshell, The more exact the point distribution and paths are, the "simpler" everything is for the control and the machine – velocities can be better planned, machine dynamics can be fully utilized, machining is faster and surface quality is better.
Aura Frästechnik GmbH develops tools under realistic conditions in the milling laboratory. Henrik Marsch, Head of Application Technology at Aura, demonstrated the advantages of the cutters tested in this way with polygonal-ground tools in the TriHF, Poton and Vilas families. These tools are especially suitable for high feed-rate milling. The "iklick" software, independently developed by Aura, enables them to offer all tool dimensions and cutting data in an electronic catalog. These data can be imported to Tebis via a direct interface and can thus be perfectly integrated in Tebis template technology.
Proven in practice
Finally, the high point of the event was the production of actual components – because the practical test proved exactly what the presenters from Röders, Aura and Tebis had previously explained theoretically in their presentations. The experts combined strategies, cutting data, tools and machines based on the material and component geometry so that the best possible result could always be achieved. Hardened material was completely machined on the RXP601DSH 5-axis milling machine. Non-hardened material was roughed and prefinished on the RXU1400 3-axis milling machine. For roughing, adaptive and contour-parallel strategies were combined and exactly matched to the specific geometry, always using the optimal cutting data. Both insert mills and HPC cutters were used. The effective milling performance was especially notable – the quality of the toolpaths was proven with the long overhang lengths of the polygonal cutters.
In pre-finishing as well, the NC program, machine and tool were perfectly integrated. High feed-rate cutters yielded very good results even for pre-finishing because the Tebis contact geometry is actually high-precision and works with a constant stock allowance. The exact point to distribution of the NC programs enabled full utilization of the machine dynamics – the result after finishing was abundantly evident.