CIMdata PLM Industry Summary Online Archive
12 June 2007
Implementation Investments
Cimatron 5-Axis Helps Tool Maker Reduce use of Electrodes by Over 30%
Cimatron Limited announced that Giebeler GmbH , a tool maker based in Eschenburg-Wissenbach, Germany, is reporting significant time savings and productivity gains with the use of Cimatron's 5-axis solution. A major portion of these productivity gains results from reduction in the use of time-consuming Electric Discharge Machine (EDM) processes.
"Thanks to the Cimatron 5-Axis solution, we use 30-40% less electrodes than we used in the past," says Markus Noll, Technical Director at Giebeler GmbH. "We can now use milling in places that previously required EDM processing; and when we do use EDM we can drastically reduce the number of electrodes."
"For instance," explains Noll, "an aluminum die-cast mirror base that used to require 8 single electrodes with 3-axis production is replaced today by a single graphite electrode milled on a 5-axis machine." The streamlined process reduces overall design and production times, as well as the material costs associated with the manufacturing of the electrodes.
According to Noll, it also helps improve product quality: "Since we are producing only a single electrode, we can minimize the number of tolerances and the potential for errors."
Marco Wolff, manager of the CAD/CAM service at Giebeler, adds: "With 5-axis machines, we can use small cutters of just 0.3mm with slim projecting holders to work out the typical deep contours. Cimatron 5-Axis Production automatically calculates a collision-free position for the tools and tool holders. We use the software to simulate tool motion and material removal on the screen before we start milling. The simulation is particularly important with the smaller cutters and smooth recesses, where the die can easily break. Furthermore, the simulation gives us a quick and reliable read to avoid a situation where some areas might be missed if too large of a tool were selected."
Using the 5-Axis technology helps Giebeler keep pace with the increasing demands of its customers. Says Wolff: "The design and interior of mirrors and lights, for example, have considerably changed in the past few years. Today, the outlines are divided into tiny parts, which are geometrically demanding due to their unique design characteristics and extremely tight tolerances. In the past, we needed up to 20 individual electrodes for some filigree parts. Nowadays, we can collapse multiple different geometries into a single one, which is only possible using 5-axis machines."
"Thanks to 5-axis technology, we have become more flexible in our manufacturing methods. The quick turnaround times which we are achieving these days on very complex products could not be realized without the use of 5-axis technology," confirms Noll.
Given the tremendous benefits realized, Giebeler has been continuously expanding the use of 5-axis technology. Today, the company operates a modern machine park with six 5-axis machines, and every new machine purchased by the company is 5-axis capable.
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