Technology partners demonstrate new approach for roughing residual stock
The Die & Mold Days exhibition took place in early May in the GROB technology and application center in Mindelheim, Germany. In two days, technology partners GROB, Tebis and MMC Hitachi Tool demonstrated how an optimally harmonized combination of machine, software and tools can produce first-class manufacturing results to more than 60 visitors.
The highlight of the exhibition was the live manufacturing of a workpiece. The workpiece was programmed specifically for the seminar using Tebis and includes prismatic machining types (2.5D) that are typical for die and mold manufacturing, ranging from deep-hole drilling to free-form machining to the production of ribs. For manufacturing, the latest tool developments from MMC Hitachi Tool were implemented on two different 5-axis machining centers from GROB. During the presentation section, the competency partners presented the machines, manufacturing solutions and tool technologies used for efficient machining. While GROB explained the benefits of the G350 and G550 machining centers, MMC Hitachi Tool presented the "Production 50" manufacturing concept, which enables cost reductions of up to 50 percent through the use of highly sophisticated and adapted tools in combination with new manufacturing strategies.
Combined roughing and finishing strategies in 52 HRC
The workpiece was so well prepared with Tebis software and the manufacturing knowledge stored in the process libraries that it could be machined automatically in both the soft and hardened state. The roughing strategies available in Tebis, as well as the use of HFC (high-feed-rate cutters) and HPC (high-performance cutters), ensure efficient roughing in the soft state. Tebis software includes process libraries that model the customer's manufacturing knowledge. For example, the libraries include tool data with the manufacturer's optimized parameters and, thus, can be used repeatedly and reliably. This results not only in perfect cutting conditions for the tool itself but also for the subsequent process. This is based on realistic modeling of the cutting geometries during NC path calculation.
Visitors were very interested in the demanding machining operations in 52 HRC. The cooperative effort of the three technology partners enabled the demonstration of a new approach for residual stock roughing in which roughing parameters and finishing strategies are combined in Tebis. The workpiece created during the technology days can be seen at the Tebis booth at the Moulding Expo.