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Since 1982, Cimatron has provided toolmakers with an end-to-end solution for designing and manufacturing tools including molds, dies, and electrodes, as well as programming any CNC and EDM machine for molds, dies, plates, and discrete manufacturing. While Cimatron is at its most powerful when used as a fully-integrated system, it also provides standalone solutions for faster quoting, tool design, electrode creation, and NC programming.
Dramatically increase your productivity, competitiveness, and profitability with a wide range of dedicated, applicative tools for mold, die, and electrode design and manufacturing, as well as a full range of CNC technologies, from simple 2.5-axis milling and drilling to complex 5-axis machining.
In addition, Cimatron offers a view-only license and special solutions and bundles for electrodes, additive molding, NC plate machining, turning, EDM setup, and education/academic institutions, plus optional add-ons for NC programming and mold, die, and electrode design and manufacturing so that you can customize your workflow.
ALPLA produce innovative packaging systems, bottles, caps and injection-molded parts for a wide range of industries. Find out from Markus Schuster, Head of ALPLA Mold shop how a company with 23,300 employees in 190 locations uses Cimatron for their tool design & manufacturing processes, and electrode automation workflow.
Find out more at www.cimatron.com
B&J Specialty Increases Production Rate by 30% with Cimatron Designed Conformally-Cooled Injection Mold. The new conformally-cooled mold inserts reduced temperature variation throughout cooling to 18C and shrank cycle time on the mold from one minute to 40 seconds, an overall productivity improvement of 30 percent.
SAVE 70% OFF DESIGN TIME, 16% OFF MOLD COST, and 14% OFF CYCLE TIME.
Scott Young, Engineering Manager at Bastech, a single-source solution provider for mold design & manufacturing, and additive manufacturing services explains how the implementation of Cimatron for conformal cooling design has introduced a new level of simplicity, efficiency, and economy to mold design.
ALPLA produce innovative packaging systems, bottles, caps and injection-molded parts for a wide range of industries. Find out from Markus Schuster, Head of ALPLA Mold shop how a company with 23,300 employees in 190 locations uses Cimatron for their tool design & manufacturing processes, and electrode automation workflow.Find out more at www.cimatron.com
Not only are the parts getting smaller, they are packed with more components to provide added power and functionality. Manufacturing small, complex parts requires machining with microtools that are delicate and can be easily deflected and broken. Cutters for micromachining do not respond to their cutting environment as their larger-size cousins do. There are a number of micromachining issues that influence the underlying mechanisms of the process, and are fundamentally different than when machining with large tools. These include changes in the chip-formation process, changed cutting forces, unusual vibrations and instability in the process and the generation and character of the resulting machined surface.
With such small part and feature sizes, accuracy takes on a new meaning. For example, a 0.0002-in. (5-m) tolerance is very different in relation to the size of a feature on a part that is 0.2 in. compared with a feature on a part that is 0.002 in.
"To achieve the quality and accuracy required in micromachining, while meeting economic and commercial constraints, the entire manufacturing chain must be optimized and synchronized," says Hari Sridharan, director of engineering at Cimatron Ltd. (www.cimatron.com), Givat Shmuel, Israel , a provider of CAD/CAM software. At a time when the production of simple and medium complexity molds is shifting to countries with low labor cost, U.S. and European moldmakers are turning to more advanced technologies such as micromolds and micromilling to remain competitive.
SMALL PARTS, BIG CHALLENGES
Among the major challenges is the direct milling of miniature-part molds and manufacturing of EDM microelectrodes. Challenges related to micromilling include the use of miniature tools with diameters down to 100 m or less, spindle speeds of up to 150,000 rpm and surface finishes as good as 0.2 m. (0.0000078 in.). And, since polishing is often impractical for fine parts with microdetails, micromilling calls for polishless machining.
WHY MICROTOOLS DEFLECT AND BREAK
Tool deflection and breakage is much more frequent when micromilling as compared with conventional milling. Ken Yap, director of Suwa Precision Engineering Pte Ltd in Singapore (www.suwaprecision.com) explains the three main reasons why micromachining tools are more apt to break.
First, when metal is removed by machining, there is a substantial increase in the specific energy required as the chip thickness decreases. This means that in the case of micromachining, as the chip gets thinner with smaller depths of cut, the microtool bit is subject to greater resistance as compared with conventional machining. It is as if the workpiece material becomes harder during micromachining. This resistance force is strong enough to exceed the bending strength limit of the tool bit even before the tool experiences any significant wear, and that can lead to breakage of the tool bit. One way to prevent this is to ensure that the chip thickness is smaller than the radius of the tool bit edge.
Second, a sharp increase in cutting forces and stress from chip clogging during the micromilling process can also cause the tool bit to break. In most micromilling operations that use a miniature microtool bit with two cutting edges, each cutting edge removes chips from the machining area only within half a rotation. However, if chip clogging occurs, within a few tool rotations the cutting forces and stresses increase beyond the limit of the bending strength of the tool bit, and it will break. For this reason, some users prefer high-speed steel tool bits because they are more flexible and tolerate clogging better than carbide tool bits.
Third, the tool bit tends to lose its cutting edge due to built-up edge, and cannot machine efficiently. As the workpiece starts to push on the tip of the tool bit, the tool bit deflects slightly. The increase in tool deflection and the stress generated by milling with every rotation eventually cause the tool bit to break. This process is also called extensive breakage.
As a result of these phenomena, most micromilling machines are sold with sensors to measure the forces acting on the tool bit, and advanced CAM software to predict the chip load throughout the micromachining process.
CAD/CAM REQUIREMENTS
Milling machines, holders and tools cannot simply be scaled down to achieve the microscopic dimensions and extreme accuracy required by micromachining, In the same way, software must be tuned and optimized for microprocesses. Creating and modifying geometry with the right accuracy, smoothness and continuity are just the entry points for a microcomponent CAD solution. CAM systems must be able to handle the tight tolerances and ultra-accurate machining. Since operators cannot interfere to prevent tool breakage, the software must consider the chip load accurately throughout the machining process.
Cimatron has introduced a NC software solution for micromilling that is available on the CimatronE 7.0 product suite. At the time of its release in 2005, the company said the software was the first commercial solution for micromilling. The software is a product of Cimatron's participation in a micromilling research project funded by the European Community and sponsored by the Fraunhofer Institute for Production Technology (IPT) in Aachen, Germany.
Because hand polishing is not an option in micromilling, Cimatron software supports high-speed milling for polishless machining. To eliminate the risk of tool breakage, reduce air-cutting motions, maintain tool load and lengthen tool life, the software constantly and automatically records remaining stock details, even at the microcomponent level. The software supports five-axis tilting to machine deep areas with conic tapered tools. The ability to tilt a tool away from the material enables using shorter tools. However, since continuous five-axis milling is currently less accurate than three-axis milling, machine specifications and actual performance must be carefully validated when using continuous five-axis for micromilling. Other features of the software include an optimized milling strategy and built-in CAD with accurate (0.001 m) surface creation and mending tools.
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