Software slashes toolmaking time

A change of software has helped automotive supplier Siemens-VDO to reduce the overall modelling and machining times for its tooling by between 30 and 40%.

The addition of Delcam's PowerShape design software and PowerMill CAM system, together with Camtek's PEPS wire erosion software, has enabled the Babenhausen site of automotive supplier Siemens-VDO to reduce the overall modelling and machining times for its tooling by between 30 and 40%.

In addition, the combination has raised the quality of the tooling and, therefore, of the resulting parts.

Furthermore, costs have been reduced by cutting the number of electrodes needed for finishing operations by 50%.

Siemens-VDO is one of the world's largest suppliers of electrical and power train equipment for the automotive industry.

The company manufactures a broad portfolio of innovative products that make vehicles safer, more comfortable, more powerful, more environmentally friendly and more efficient.

It supplies systems for virtually every German car manufacturer as well as a growing international business.

As part of its operations, a wide range of toolmaking operations are undertaken, including single- and twin-shot moulds for plastics, and press tools and trimming tools for sheet metal components.

"The main reason for choosing to buy from Delcam was that the Power Solution software provided a much more integrated system than our previous mix of software", commented Karl Rosinger, Leader of the CAM-Department.

"It could also be used alongside Camtek's PEPS wire erosion software to give a complete solution for all the toolroom's needs".

"In addition, the Delcam products seemed to be much easier to use.

PowerShape, for example, had a much more modern interface than the other systems, while the intelligent cursor meant that editing of the models could be undertaken with far fewer operations.

The software was very tolerant of imperfect data with small gaps, while any larger problems could be repaired quickly".

Similarly, PowerMill was much more flexible than the company's existing machining software, with much easier editing of the toolpaths.

In addition, the 2D programming capabilities were much better.

The main benefit for Siemens-VDO is that the combination of Delcam and Camtek software has removed the previous restrictions on the work that could be undertaken.

On average, the overall time from receipt of the component model to the completion of machining has been reduced by between 30 and 40%.

"This has been possible partly because the Delcam software saves time in preparing mould designs and in programming the toolpaths, and partly because the strategies in PowerMill allow machining times to be reduced", explained Rosinger.

The additional strategies in PowerMill have also improved the quality of the machined surfaces so hand finishing has been reduced, especially when producing the extremely high-accuracy finish needed for visible, optical components.

The introduction of automated assembly operations has also made high accuracy essential for internal parts that will never be seen by the customer.

Another benefit has been huge savings in time and cost resulting from a 50% reduction in the number of electrodes required to produce fine detail in the moulds.

Those electrodes that are still needed can be manufactured more quickly by using a combination of PowerMill and a Roders high-speed machining centre.

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