Advertising in MoldMaking Technology offers
Issue link: https://mmt.epubxp.com/i/917019
Case Study / Topic 38 MoldMaking Technology —— JANUARY 2018 Case Study / Machining could hang while they burned engravings and other details onto the workpieces. The process was very time-intensive and expensive. "Our EDM tanks are large enough, but it requires special, multiple setups to get into those tight areas," she says. It gave the company one more reason to invest in the Diamond 30. "It has a linear drive for better stability, so we have no trouble meeting customers' specified tolerances," she says. "The workpiece is stationary on the platen, and the cutting tool hangs down from the gantry so that it can move in X, Y and Z directions. The small, five-axis machining head rotates and tilts to get into corners and other tight spaces that otherwise would require EDM work." Hagey says that the X, Y, and Z axes are all run on linear guide-ways using linear motors. "These motors offer notable acceleration, reliability and consistency while machining. The A and C axes utilize direct torque-driven motors for increased machining power and accuracy," he says. "These axes, including the X, Y, Z, A and C, are all measured using Heidenhain optical scales, making it possible to achieve a resolution of 0.001 millimeters (X, Y, Z) and 0.001° (A, C), respectively." The Diamond 30 also features a third guiderail, which, together with Parpas's patented Thermostatic System, improves the stability of the machine's ram, especially when it is fully extended. He adds that because the TOE-29 head makes it possible to use shorter tools, additional advantages come into play. Advantages include less vibration between the tool and the milling piece, better machined surface qual- ity, higher machining feed rates and reduced wear overall on the tools that are used. Neibarger attests to those benefits. She says, "Now we are able to machine all required details onto the workpieces using the Diamond 30, with almost no EDM required. We added Delcam's FeatureCAM software, which gives us the ability to loop programs together and not worry about a collision, particularly when we run lights out." She says that the company's goal is to be able to accomplish CNC finish machining on the mold's B side, and reduced polish- ing on the A side using lights out operation and reduced EDM. "With our larger molds, there might be 1,900 hours of machining required and only 16 weeks or fewer to build a job, so we have to be able to run 24/7 confidently. We still do some outsourcing, but not nearly as much," she says. Neibarger shared a recent project that illustrates several of the advantages that the Parpas Diamond 30 brings to Model Die's operations. "We recently built two large, deep tools that were mirror images. The cavity size was 30 inches deep by 52 inches by 80 inches. We machined everything on the Diamond 30," she says. "Five years ago, we built two nearly identical molds with the same cavity size on equipment that was more than 10 years old." When Model Die compared the actual production data between the two projects, they dis- covered that: • CNC machine hours decreased by five percent because of the Parpas's ability to reach and machine ribs and tighter areas with its smaller head and shorter tools. • EDM hours decreased by 70 percent. • Lights-out CNC machine hours increased by 10 percent, largely because the Diamond 30 has an automatic tool changer, which spared someone from having to stop in to change out tools. • Polishing decreased by 27 percent. • The Diamond 30 achieves a finer finish. "Our overall mold-building time has been reduced by two weeks because of the Diamond 30," she says. "It's really been a game changer." FOR MORE INFORMATION Model Die and Mold Inc. / 616-243-6996 sales@modeldie.com / modeldie.com Parpas America / 248-253-6000 thagey@parpasamerica.com / parpasamerica.com This image shows how the Parpas Diamond 30 features a generous table size for machining very large cavities and cores. With its orthogonally designed Model TOE-29 head that features a longer snout, it can reach into difficult-to-machine areas using shorter cutting tools. For Model Die and Mold, these capabilities have been a game changer by helping win new work and enabling more work done in-house.