TOOL, MOULD & DIE MAKING FOLLOWING THE CURVE
hundredths of a millimetre.
Once the 3D model of the mould has
been de ned, the next step is the
generation of toolpaths using NX CAM, which
can handle all necessary machining
operations, including 5-axis milling, die-sink
and wire EDM, plus turning.
NX offers a virtual machining capability
that enables NC programmers to perform
kinematic simulations that use the machine
and controller models (and machining code)
to check for possible collisions and clashes
before metalcutting begins. These features
are essential for safety and ef ciency,
enabling Mec-Plast engineers to check the
G-code le of the machining process for
reliable simulation. The simulation results
accurately re ect the post-processed NC
code in its native format. Normally, the postprocessor
applies modi cations approved by
the customer, so simulating the operation of
5-axis machines after post-processing helps
assure total safety.
“With NX, you always nd a way; anything
you design can be machined safely,”
Missaglia emphasises.
LISTEN, LEARN, ADOPT
Away from the world of software, a British
automotive manufacturer is discovering the
advantages that can be leveraged when
using 3D printing for wits tooling
requirements. Based near Birmingham,
Dunlop Systems specialises in anti-vibration
solutions, including automotive air
suspension components
and electronic control
systems for OEM and
aftermarket vehicle
applications.
Mark Statham,
production engineering
manager at Dunlop
Systems, is in charge of the
tooling used to make the
company’s products. Dunlop
Systems had a lot of old machinery and inhouse
tooling that had to be replaced
frequently. Internal and customer tools were
sent to a third-party toolmaker to make.
However, as a result of customer design
changes, costs spiralled without being
completely recoverable.
To begin addressing the issue, Statham
attended a seminar about 3D printing where
he heard about an industrial 3D printer
capable of printing in carbon bre. He
realised he could use it for tooling, as the
material was robust enough to withstand
corrosive environments. That same day, he
went to his director’s of ce and said that if
he did not buy a Markforged Mark Two, he
would regret it. His director approved the
purchase.
Since installation, the team has found
several applications for the machine,
including many gauges and moulds. The
Onyx material and continuous carbon bre
have proved a good t for the company,
providing strong, lightweight parts that can
be easily printed on the Markforged printer,
which offers a build volume of 320 by 132
by 154 mm. “We’re now going to replace all
our tooling with Onyx,” says Statham.
Usually, the department spends around
Prototype tooling, made via 3D printing,
used to assemble suspension parts for an
electric vehicle at Dunlop
£20,000 on tooling alone. In 2019,
however, the total spend estimate is only
£11,000, thanks to 3D printing. The
Markforged Mark Two is available in the UK
from HK Additive, a division of HK
Technologies (https://is.gd/aliqum), part of
Engineering Technologies Group.
Latest products in brief
As the manufacturing of dies is very
vulnerable to temperature changes, Okuma
has equipped its latest MCR-S doublecolumn
machining centre with the
Thermo-Friendly Concept, while another
function, ‘Hyper-Surface’, is said to make
manual post-processing obsolete. The
MCR-S achieves metal removal rates of
710 cm/min when face milling. In terms of
capacity, X-, Y- and Z-axis travels extend
from 4,200 by 3,200 by 800 mm (W-axis is
1,000 mm), to 6,700 by
3,700 by 800 mm (1,200
mm W axis). The UK agent is
NCMT (
https://is.gd/pucuxe).
Under a joint sales cooperation
operation with Boehlerit,
Horn Cutting Tools has
introduced to the UK
market an expanded 3D
milling programme for the
tool and mouldmaking
industry. The ISO 00P
universal tool system
features inserts mounted
in a neutral position in the
toolholder, which is said to
ensure a high level of
contouring accuracy.
The
Waldrich
Coburg
Taurus 30
Gemini from
Kingsbury
Despite the neutral position, however, the
edge geometry enables a soft cut to be
achieved. More details: https://is.gd/upotuz
Waldrich Coburg, which is represented in
the UK by Kingsbury, will add new a model
to its Taurus of machining centres this year.
Taurus models are described as small,
portal-type machining centres, but with axis
travels of 5,000 by 3,500 by 1,500 mm
and 6,000 by 4,000 by 1,500 mm, plus a
2,000 mm W-axis, they are large by typical
standards. The Taurus 30 Gemini, an
alternative version of the larger of the two
existing machines available, is suited to
mould and die production: it is able to
perform both roughing (63 kW/1,500 Nm
spindle power) and high speed nishing
(20,000 rpm spindle speed).
More details: https://is.gd/gakotu
Dormer Pramet has expanded its milling
line for mould and die with introductions
including the newly developed double-sided
SNGX11 insert for high-feed milling at up to
1.7 mm depth of cut. A strong main cutting
edge ensures high levels of durability and
process security, especially in machining
pocket corners. Suitable for copy milling,
helical interpolation, ramping, progressive
plunging and face milling, the SNGX11 is
available in two geometries. M is for steel,
as well as hardened steel and cast iron,
while the MM version delivers a smoother
cut and is more suited to stainless steel,
soft steel and super-alloys.
More details: https://is.gd/ujafef
www.machinery.co.uk @MachineryTweets January 2020 43
/gakotu
/pucuxe)
/upotuz
/ujafef
/www.machinery.co.uk
/aliqum