Utilising the design information supplied from the tooling model, impression forms are rough machined. High speed Ethernet connections communicate gouge free, accurate toolpaths produced by industry leading software to the 5 axis and vertical machining centres.
All impression forms are finish machined after heat treatment to ensure their accuracy leaving spark erosion for the deeper finer detailed area's.
5 axis machining
Inspection of machined impression form and spark erosion electrodes are undertaken using Autodesk Powerinspect 'on machine verification' software using Renishaw OMP60 and OMP40 probes.
The probe and software are used to verify the accuracy of the machined 3D surface or 2D feature by comparing the measured surfaces back to the CAD model and report on any deviation. If the machined impression or electrode is found to be out of tolerance and requires additional machining this can then be recut without removal from the machine and re-checked for accuracy.
PowerInspect 'On Machine Verification'
DMG MORI DMU 70 EcoMill 5 axis milling machine.
Heidenhain 620 control, 12000 rpm spindle, 20 Bar through spindle coolant,
750 mm x 600mm with a 800mm dia. table, 30 tools, Probing and Renishaw tool measurement.
DMG MORI DMU 75 monoBLOCK 5 axis milling machine.
Heidenhain 640 control, 20000 rpm spindle, 40 Bar through spindle coolant, HSK 63, 60 tools,
X 750 x Y 650mm 650mm dia. table, 600kg machine capacity.
Probing and Blum Laser tool measurement.
Haimer Power Clamp for Shrink fit tooling.
Agie Compact 3 CNC Spark erosion machine with C axis 800 x 600mm (table size)
Autodesk Power Inspect 'On machine verification' 3 and 5 axis inspection utilising Renishaw OMP40 and OMP60 probes
Bridgeport VMC 610 xp2 Heidenhain 530i control, 15000 rpm spindle 610 x 500 x 600mm.
2 Sparcatron SM36 Spark erosion machines with CNC Orbiting. 900 x 600mm (tank size)
System 3R Macro pallet, Macro Junior and Mini electrode systems ensure fast and accurate transfer of electrodes between milling and erosion machines.
Nakanishi NSK 40 000 rpm Electric spindle
NCG CAM - 3 and 3+2 Multi-surface machining .
3D solid and surface design software.
Short video of the machining of an aluminium carbon fibre mould - https://youtu.be/KMIWdhzrXBU
Please copy hyperlink to view video.
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