Even complex metal components are designed on the computer. © Kauth mechanical engineering

The process at Kauth Werkzeugbau begins with "colleagues from Denkingen approaching us with a new part," says Schläfle. In addition to general explanations, the geometry data is available in Solidworks format. The designer uses this to create a method plan and a suggestion as to how the strip layout should look. The Logopress software, which is also integrated in Solidworks and supplied by DPS, is also helpful at this point. Logopress supports tool design, strip layout, processing and free-form processing. Once the results mentioned so far are available, a calculation and quotation are prepared on this basis. "If our prices weren't right, for example if we were much more expensive than the competition, we wouldn't get the order either," says Alexander Schläfle confidently.

If approval is given, the tool is built in Solidworks. At a degree of completion of 80 percent, a control step takes place: the client receives the results and carries out a kind of preliminary acceptance. Only after the OK is given are the tools completely designed and the final acceptance follows. Once the design process and approval have been completed, the drawings are derived.

Then comes the transition to production, and Solidcam comes into play. There are now five workstations on site with the software installed - three for design and two for CAM milling. The NC programmer therefore no longer has to carry out any transfer measures, but can call up all the necessary workbars by clicking on the "CAM" button and start them directly.

The software uses the 3D raw model data and the CAD geometry of the finished part for input. © Kauth mechanical engineering

Another positive feature is that all machines and tools are stored in libraries. The operator simply drags them into the working plane and inserts them. This then allows a complete simulation: table in the way, holder in the way, vice in the way; everything comes out in the simulation. "Simulation is required for 5-axis milling at the latest. The possible movements are so complex that they can no longer be overlooked by the operator," explains Schläfle. Solidcam is mainly used at Kauth Werkzeugbau for the program supply of Hermle machining centers. The machining types are milling and drilling. The post-processors are done by DPS, so that the data flows smoothly to the machine. The resulting accuracies are sufficient to reliably machine even demanding tool parts.

Roughing in synchronization

For some years now, CAM manufacturers have been offering special programs for roughing in climb milling. One of these packages is iMachining from Solidcam, an automatic CNC program generator for high-speed milling for roughing, residual material roughing and rough finishing of prismatic and flat-shaped 3D parts.

The software uses the 3D raw model data and the CAD geometry of the finished part for input. The system does the rest itself. However, this is only possible using information stored in the database, including tool data, material data and machine data. From this information, iMachining creates a high-speed CNC program. The system's algorithm ensures that the same chip volume is always removed per milling tooth. This ensures that the tool is optimally utilized. At the end of the process, an average time saving of 70 percent is achieved. Of course, this value depends on the respective tasks. In addition to the time savings, the focus is on tool protection, which leads to an increase in tool life of up to a factor of 3, especially with difficult-to-cut materials.
Kauth Werkzeugbau also uses this software, but not across the board. "We also use so-called high-feed milling cutters for fast roughing, which are also very productive and represent an alternative," says Schläfle. The CAM programmer decides which type of roughing to use based on his experience.

Karl Obermann, freelance editor for Dassault Systèmes / ag