Product category:
CAM, CNC and production management software
News Release from: Pathtrace Engineering Systems | Subject: EdgeCAM
Edited by the Engineeringtalk Editorial
Team on 17 September 2002
CAM software reduces risk of gouging
Life is a lot easier for Suffolk-based Haverhill Mould and Tooling following the installation of EdgeCAM computer aided manufacturing software.
One of the concerns always facing Suffolk-based Haverhill Mould and Tooling in its manufacture of plastic mould tooling, press tools, blow moulding and diecasting tooling was the risk of gouging the machined or adjacent surfaces with the cutting tool while 3D machining "That can ruin a very expensive component", insists Nigel Farenden, Managing Director
This article was originally published on Engineeringtalk on 3 May 2000 at 8.00am (UK)
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However, following the installation of EdgeCAM computer aided manufacturing software from Pathtrace of Reading, Nigel Farenden maintains life is a lot easier and any previous concern or problems associated with gouging have disappeared.
"With EdgeCAM we can totally rely on any code generated", he said.
The Suffolk-based precision engineering company largely specialises in 'concept-to-completion' projects.
To that end, it has a well-equipped machine shop with CNC machining and EDM sinking facilities, capable of manufacturing tooling weighing up to three tonnes.
The company has its own try-out/pre-production and production moulding shop with plastic injection moulding machines having up to 330 tonnes locking force.
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In addition, Neil Farenden, who is principal programmer, sometimes has to provide CNC program development for third party companies.
As Neil Farenden comments: "We've used Pathtrace's offline programming for some time.
We started with a PAMS system and have religiously upgraded to take maximum advantage of any new developments.
As a result, we know the system very well.
The latest version of EdgeCAM is far superior to anything that went before in terms of its capability to position and visualise a 3D model.
We can also take in SolidWorks generated 3D models without using a translator".
He describes: "With EdgeCAM we now have total flexibility to check the whole part on-screen and through the browser at the side of the screen, we can add descriptive names to each layer.
If we need to adjust or amend the program, it is so easy when you know exactly where to start".
A high proportion of Haverhill's tool work is related to optical moulding for vehicle lighting systems and commercial lighting applications.
This is very demanding with tolerances having to be maintained within 0.012 mm.
Equally, many of the other applications require development of complex tools incorporating sliding cores or are based on modular formats which enable a variety of components to be moulded from one basic toolkit.
The lead time on injection mould tools, which tend to be fairly complex, is kept to an average of six weeks by developing the tooling and CNC programming in parallel with the manufacturing process.
The normal method of mould cavity production is to machine as much as possible on the company's CNC mills and machining centre, then finish the cavity using vertical EDM to produce features such as sharp internal corners that cannot be created with a milling cutter.
Farenden explains how the company hardly produces any two dimensional moulds.
"Most comprise complex surface geometry involving considerable tool design or product redesign before we can even set about making the actual tool", he says.
Much of the company's work involves redesign, which means it is only half a dozen or so times a year when machining can be carried out straight from the client's model.
More often than not, Farenden has to redefine split lines and rework the component geometry to ensure the moulding process is both practical and efficient.
"This means that EdgeCAM's excellent model import and rendering facilities really do improve this part of the process", he insists.
He then outlines how with EdgeCAM, he has the capability to break a component up into discrete surfaces giving benefits such as better surface trimming.
Moreover, machining strategies, such as providing the choice of infeed approach, are important and the advanced machining capabilities enable a consistent finish to be dictated across both sloping and flat surfaces.
In addition, the z-level finishing capability is seen as being especially effective.
Once a machining program is developed in EdgeCAM the data is downloaded via DNC and drip fed when the programs are larger than the available memory space on the machine tool control.
In particular, the EdgeCAM code wizard post processing system provides the opportunity to make use of resident control features such as rotation and repetition.
"This allows complicated forms to be machined using relatively short programs, which also means we have the benefit of running much faster", says Farenden.
Haverhill makes considerable use of code wizard and has developed a special pecking cycle to ensure a constant moulded depth can be maintained.
This has proven to be particularly effective on features such as the dimples in automotive stop lamp and indicator lenses which are critical in the design to precisely spread the light pattern.
In EdgeCAM, Haverhill Mould and Tooling has found a very powerful programming tool that allows its tool development and mould machining to be carried forward with very high levels of confidence.
"I know for certain that if a program works on the screen then it will reproduce on the machine.
That counts for a great deal in productivity, improved security, confidence and especially the bottom line profitability on the job", he concludes.
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