Creating rotational mould tools using high-end software

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Simulation confirms machining accuracy

“Once we know that our design will work, we import it into Edgecam and apply the machining strategies. Then we run it through Edgecam’s powerful simulator to make sure there won’t be any expensive collisions when we start cutting metal. When we’re happy that we’ll be able to machine the mould tool exactly how we want it, we create the NC code with any chosen post processor.”

“It’s one thing to design a mould tool, but Edgecam gives us full confidence that it can also be machined accurately and quickly. Depending on the size of the mould, the turnaround time is usually between two and 12 weeks.”

Kevin Rees says that Edgecam makes the task of machining rotational mould tools’ particularly complex features, an easy process. “This is because any shape within Edgecam becomes simple. Even with the most demanding shapes, the only complexity is how quickly Edgecam can process the information. It handles several millions lines of code just as easily as a few thousand – it just takes a little longer.”

As well as investing in two additional Haas VF4 SS machines for high speed machining at 12,000 rpm, which are perfect for their aluminium rotational mould tools, the company have installed a new six dual-core computer capable of running 12 x 3.5 gigahertz simultaneously, which he says is vital to handle the huge file sizes.

It also has a solid state hard drive, 31.9 gigabytes of RAM, and NVIDIA Quadro K4200 graphics card.

CNC miller Alexey Don has been working on the pipe mould tools, saying Edgecam not only made the job simple...it made it possible in the first place. “With millions of lines of code it would be a lifetime’s work to do it manually. We just wouldn’t be able to work out the co-ordinates. But Edgecam does it within a couple of hours.”

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