TEBIS精细化模面设计

24.02.2025Folie1

„AnwenderberichtDemo-BauteilVideoTebis精细化模面设计高质量的模面设计优化加工与试模流程Tebis在冲压模具制造流程中的应用试模加工制造数控编程编程准备加工规划冲压厂矫正装配数据输入模面设计接口SynchronizationDigitizediesaftertry-outReverse-engineermodifiedareasCorrectdiesurfacesForanefficientcorrectionandchangeprocess,itmustbepossibletotakemanualdiecorrectiontimesbacktotheCADdataatanytime.TothedetailsDesigndataCreateCADdataTheresult:CADdataofthecomponentTothedetailsDiedesignDeterminethediestructureDesigncastpartsandinsertsTheresult:DesigneddieatcastinglevelTothedetailsInterfacesFastimportandwithoutdatalossfrom,CATIA,NX,SolidWorks,andmanymoreviastandardinterfacesTheresult:TransferofallstructuresfromothersystemsinTebisTothedetailsOverbendingDeformsurfacesusingvariousrulesCreatecorrectiondataCounter-simulationtoconfirmtheoverbendEffectiveandreliableimplementationofnecessarycomponentcorrectionsontothediesurfaces.TothedetailsProcessingdiesurfacesIntegratespottingsurfaceswithouttransitionsClearradiiOptimizesurfacesArrivequicklyatanevenspotimageinthepress,simplifyprogrammingprocessesandshortenthroughputtimes.TothedetailsManufacturingdesignCombinediesurfacesandsoliddataGenerateblanksStructureforautomatedprogrammingStandardizetheprocessingforNCprogrammingandsupportautomaticprogrammingprocessesTothedetailsCastpartmeasurementDigitizecastpartsCreateroughingprogramsTheefficientandprocess-reliablemillingofcastparts.Tothedetails2.5DNCprogrammingApplytailoredprogrammingmethodsforpocketandholemachiningAutomaticprogrammingwithvariableNCtemplatesAutomaticallycreatedrillingandmillingprograms"attheclickofabutton".Significantlyreduceprogrammingtimesduetofeature-based2.5millingandincreasetheprocessreliabilityatthesametime.TothedetailsMachiningtoolselectionWithToolControl,youalwayshavetherighttoolatthemachineAlignCAMtoolswithrealtoolsAdjusttoolmagazinesReducingthenumberoftoolvariants.Significantlyreduceprogrammingtimesduetofeature-based2.5millingandincreasetheprocessreliabilityatthesametime.TothedetailsTrimandcoiningsteelprocessMultiplesetupofsmallcomponentsCompletemanufacturingofallsetupsCollision-checkedprogramsIncreasemachineruntimesandreducedowntimesindraw-diemanufacturingbyusingthemultiplesetupoftoolcomponents.TothedetailsLargecomponentmanufactureRougheffectivelythankstocastpartdimensioningPrefinishaccuratediesurfacesusingHPCmillingtoolsSignificantlyreducemillingprocesstimesbyusingHFCtoolsandtakingthecorrectcuttergeometryintoaccount.TothedetailsAssemblyPreciseassemblyofmanufacturedcomponentsPaperlessaccesstodesignandmanufacturingdataTheresult:PrecisediesTothedetailsManualcorrectionsTransfersurfacesControlpressingandspottingsurfacesIntegratesubsequentoperationsTheresult:SpottingeffortreducedtoaminimumTothedetailsSpotimageProducedrawncomponentsCheckspotimageTheresult:OptimalspotimageTothedetailsQualitycontrolMeasuringgaugesanddigitizationEvaluatesurfacesTheresult:MeasurementprotocolandcorrectioninformationTothedetailsCorrectionsIntroducecorrectionloopsUsemeasuringpointsforcorrectionsTransparentlydeformdiesurfacesTheresult:ShortenedprocessthankstominimalcorrectionsTothedetailsPressingplantQuicklytransferprocess-reliabletoolstothepressingplantTheresult:OptimaldiemanufacturingprocessTothedetailsMethodandsimulationDevelopamethodconceptSimulatedeformationforcheckingfeasibility,springback,andprocessreliabilityTheresult:3DmethodplanverifiedthroughsimulationTothedetailsNCtemplatesSaveknow-howinlibrariesProvidecompany-specificknowledgetoallpartiesinvolvedWorkwithstandardsTheresult:StandardizedprocessesTothedetails3DNCprogrammingApplytailoredprogrammingmethodsfor3DsurfacemachiningCreate3-and5-axisNCpathsAutomateNCprogramsusingtemplatesTheresult:CompleteprogramsforsurfacesTothedetailsTothedetailsEnd-to-endmachinesimulationPlan,test,andoptimizewithvirtualmachinesDefinesetuporientationandtoolsCorrectwithoutrecalculatingFlexiblyoperateallmachines,fromthesmallesttothelargestTheresult:Processreliability,fastthroughputTothedetailsTothedetailsMeasurementonthemachineQualitycontrolintegratedat100percentMillingandmeasuringinasingleNCprogramOptimalutilizationofthemachinepotentialTheresult:Morereliabilityandfasterprocessthankstocollision-checkedmeasuringpathsTothedetails规划与数据管理24.02.202524.02.2025Slide3

Activesurfaceprocessintoolanddie试模加工制造数控编程编程准备加工规划冲压厂矫正装配数据输入模面设计接口精细化模面设计流程24.02.2025Slide4

快速完成模面的设计和准备使编程更加容易加工出最优的模面减少试模时的重复工作Link:TebisActivesurfaceprocess实际情况应用目标缺陷收益解决方案工程模，传递模，级进模结构件模具，外板件模具试生产和批量生产内部使用模具或商品模具新模具开发和模具的修正适用于所有的成型模具和修边模具精细化模面设计流程

24.02.2025Slide5

实际情况应用目标缺陷收益解决方案钳工手工补偿模具由于料厚减薄产生的间隙料厚的附加偏置由NC偏置完成模具型面上会有尖角产生试模需要很高的人工干预精细化模面设计流程

拉延时的料厚减薄试模时需要很多人工对型面进行修正！24.02.2025Slide6

加工后产生尖角试模时手工打磨附加料厚偏置实际情况应用目标缺陷收益解决方案人工干预模面，错误率提高NC设置偏置容易产生干涉问题模具周期不能保证容易产生重复工作精细化模面设计流程加工后产生的尖角试模时人工打磨24.02.2025Slide7

实际情况应用目标缺陷收益解决方案精细化模面设计流程增强圆角减小功能偏置区域平滑过渡增强CAD和CAM的曲面准备功能修边线刀块自动避空ManufacturingTryoutNCprogramming模面设计接口24.02.2025Slide8

Activesurfacepreparation结果：模面实现平滑过渡实际情况应用目标缺陷收益解决方案精细化模面设计流程24.02.2025Slide9

加工试模NC编程ActiveSurfaceInterfaces通过刀路偏置实现间隙补偿通过模面设计实现间隙补偿实际情况应用目标缺陷收益解决方案精细化模面设计流程编程时无需再考虑间隙补偿NC仿真更加真实可以使用高速切削刀具（HFC）进行粗切，半精切和精切在机床上优化进给模具型面没有台阶，优化试压结果24.02.2025Slide10

结果：降低模具生产中的重复工作HFC-MachiningActiveSurfaceInterfaces实际情况应用目标缺陷收益解决方案加工试模NC编程精细化模面设计流程质量模具表面质量更加优化优化刀路NC编程不考虑偏置减少试模工作量模具型面都是光顺过渡安全真实的曲面编程和曲面仿真节省时间试模的重复劳动减少24.02.2025Slide11

实际情况应用目标缺陷收益解决方案精细化模面设计流程Reducedtimeforsurfacepreparationupto50percentconparedtomanualprocessesandsoftwaretoolsFastenmachiningduetoHFCcutters15percent

inanaverageRedecingtryouttime25percent(fordrawdiescomparedtoprocesseswiththicknessattributes)ExampleDrawdieforBodysideEffort(oldprocess)EffordNEW(TebisActivesurfaceprocess)Totaleffort(perdie)Saving(perdie)Activesurfacepreparation16hperdiecomponent8h

prodiecomponent48h24h

less/50percentfasterNCprogrammierungxxhperdiecomponentxxh

perdiecomponentxxhxxh

less/xxpercentfasterManufacturing200hperdie

component165hperdiecomponent380h60hless/15percentfasterTryout(grinding)400hperdie

component300hperdiecomponent400h100hless/25percentfasterTebis是一套流程!我们为共同的目标而努力。24.02.2025Slide12

ActualsituationApplicationsObjectivePainBenefitSolution模面设计–附加信息24.02.2025Slide13

MarketsituationActivesurfacesCampaign2016:TebisismorethanjustNCprogramming.SimplifyNCprogrammingwithCAD,andreducemanualreworkExtendTebisexistinginstallationstowardconstructionDisplaceexistingdesignprocessesandsystemsTebisisapioneerintheissueof"reworkfreetool"Consu