MoldMaking Technology

JAN 2018

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Software 24 MoldMaking Technology —— JANUARY 2018 A new trend that is emerging in simulation software is the ability to simulate any manufacturing process (additive, milling, turning, welding and so on) in the order used to fabricate a part. This image shows a simulation of laser-directed energy deposition (DED) used in a multi-operation manufac- turing process. industry. Simulation experts say that simulation software is becoming easier to use and more diverse in its applica- tion to meet the increasingly diverse needs of moldmakers. Gene Granata, Vericut product manager at CGTech (Irvine, California), says that a continuing trend is to educate and energize the moldmaking industry about the prospects of using additive manufacturing (AM) to manu- facture better molds and to achieve faster times to market. "As more mold companies move to adopt AM, simulation software is offering more variations of additive motion paths and is attempting to predict heat distortion and material deformation that could pose problems during the build process," he says. "These advance- ments are driven by the need to build additive parts that not only have sound functional design, but also have sound structural integrity." Granata says that addi- tive building and pro- gramming software is becoming more robust. With that, a new trend is emerging for simulation software developers for subtractive and additive processes—software is making it possible to simulate any manufacturing process (addi- tive, milling, turning, welding and so on) in the order used to fabricate the part. This more "global" view of verifica- tion can expose potential "surprises" between operations and ensures that the final part (after moldmakers perform all operations and processes) is correct and is made as efficiently as possible. "The need for more comprehensive simulation stems from the fact that many additive process- es still require post-process machining to achieve desired tolerances and surface finishes on at least some mold features," he says. Another trend is the emergence of more varieties of hybrid machine tools (machines that can add and subtract material). Hybrid machines can be a mixed blessing, Granata says. While they are certainly more capable than their non- hybrid counterparts, they also have many more functions and NC codes that moldmakers must properly manage. Hybrid machines require different NC programming tech- niques than those with which most NC programmers have familiarity, and they come with new safety hazards such as dangerous, high-powered laser equipment and potentially caustic powdered metals. "Simulation software makes it pos- sible to test various manufacturing methods and determine which will produce the best part while maximizing use of the available CNC equipment," he says. In order to do the best job, users will want to choose simulation software that is driven by the same NC code that will drive the machine, thereby ensuring the highest level of verification possible. "We believe the next logical advancement AM adopters will need is the ability to optimize the additive and hybrid processes," Granata says. "Simulation software is already available to optimize machining based on optimal chip loads, cutting forces and so on. But, what about additive? Moldmakers who are using AM will want to know that they are applying material as quickly and efficiently as possible and within the limits that their additive material and CNC Image courtesy of CGTech. Simulation software is already available to optimize machining based on optimal chip loads, cutting forces and so on. But, what about additive?

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