Tooling  Manufacture

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          
 

                                          

        

CNC and manual spark erosion machines utilising CNC orbital heads give an improved surface finish while the System 3R Macro pallet system ensures fast and accurate transfer of electrodes between milling and erosion machines.

Inspection of impressions and spark erosion electrodes are undertaken using Autodesk Powerinspect  'on machine verification' software using a Renishaw OMP60 probe. The probe and software are used to verify the accuracy of the machined 3D surface or 2D feature back to the CAD model and report on any deviation. If the impression or electrode 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.

  • Autodesk Power Inspect 'On machine verification'  3 and  5 axis inspection

  • Bridgeport VMC 610 xp2  Heidenhain 530i control, 15000 rpm spindle  610 x 500 x 600mm.

                          

                                    Haimer Power Clamp for Shrink fit tooling.

  • Agie Compact 3 CNC Spark erosion machine.

                               800 x 600mm (table size) 

  • Renishaw  OMP40 and OMP60 Probes for OMV inspection.

  • 2 Sparcatron SM36 Spark erosion machines with CNC Orbiting. 

                                 900 x 600mm (tank size)

  • System 3R Macro pallet, Macro Junior and Mini electrode systems

  • Nakanishi NSK 40 000 rpm Electric spindle

   

                                             CAM Software

             

                          NCG CAM  - 3D Multi-surface high speed machining .

              

                   Visi- Machining Strategist - 3D Multi-surface high speed machining.

            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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