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Bottle Mould

Eliminating hand polishing

In today’s production environments the post-processing stages after milling add a great deal of risk and higher costs to finished parts.

In order to minimise these processes, we need better surface quality directly from the machine. Easily said, but hard to achieve. So how do we do it?

In this case, our sample has the following specifications:
 
Size  Ø115 x 40 mm
Material  A7075 (40HRC)
Machining Time  01 hours 50 min
Tools  8 tools by 5 kinds
Eliminating hand polishing

Maximising rigidity

The first part we need to fix is the rigidity of the system. The combination will be as rigid as the weakest part of the assembly.

For producing this part we used a D200Z 5-axis vertical machining centre. In the picture you can see the portical type of construction.

The linear axes are divided between the table (Y axis) and spindle (X and Z) to reduce any imperfection propagation in the chain.

The rotary axes are constructed in a knuckle-type configuration, but with a slight difference in the Z-type table. Its 45 degrees angle makes it extremely rigid with respect to perpendicular and axial forces.

The rotary axes are constructed in a knuckle type configuration, but with a slight difference, the Z type table. The Z type table has a 45 degrees angle which makes it extremely rigid to forces in the perpendicular and axial direction.
Maximising rigidity

Software - Perfect the simultaneous movement

5-axis simultaneous movement means a high degree of stress for a machine tool. All 5-axis machines have to be perfectly synchronised and follow the NC program at the speed the CAM programmer set. In addition, there is a good deal of imperfection coming from the NC program, e.g. errors in the 3D models and too few points for a perfect definition of the shape. That is why our D200Z uses the unique properties of Professional 6 to smooth out all these issues:
  • GI-Scratch - Scans the NC code to look for imperfections that normally come from the 3D model, e.g. sewing errors between surfaces in the 3D data
  • GI-Smoothing - Traditional NC controls smooths toolpaths, Professional 6 smooths surfaces! The NC control scans the program and modifies it.
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