This mold manufacturing slide of tool steel, weighing almost 150 kg, was manufactured on a DMC 80 FDS duoBLOCK. The challenge: To optimally manufacture this huge part in the very tight machining space where the machine was housed. With exact planning, precise simulation, and perfectly calculated toolpaths, it was possible to take consistent and full advantage of the available machining area.

• Safe in limited spaces: The realistic simulation took the complete machine into account, including limit switches. This made it possible to get the utmost out of the available traverse paths and avoid unnecessary retract movements.

• Efficient roughing: Adaptive roughing strategies with spiral plunging ensure high material removal and uniform tool loading. Optimized paths and appropriate cutting data extend tool service life. 

• Fast and high-quality finishing: Circle-segment cutters allow larger path distances with high surface quality. Flanks and radii can be machined efficiently; on the reverse side, this can even be done with only one barrel-shaped tool. 

• Optimally combine machining strategies: From 3-axis machining through slot and residual stock machining up to finishing – strategy, tool, and machine kinematics are specifically adapted to each machining simulation.

• Test dimensional accuracy directly on the machine: The measuring probe is used to check the machined surfaces for dimensional accuracy. That means that quality testing is performed directly within the manufacturing process.