Tool and mold making emerge at the crossroads of burgeonting product diversity and simultaneously plummeting product cycle times. Reducing throughput times is highest on the order of priorities while simultaneously driving down manufacturing expenditures is only possible by redesigning and enhancing the entire process chain. Extensive analyses of production routines form the basis for discovering potential enhancements and laying the basis for creating future production and machine designs. The method applied is broken down into:
It is not only necessary to apply the effects of state-of-the-art technology and the potential of cutting materials to downscale production times in metal-cutting production. It is also necessary to analyze and enhance the current production process. We can discover time reserves by enhancing technol¬ogy, engineering and organization. The points of concentration in relation to the analyses are:
There is a heated debate going on these days on the potential for boosting productivity and accuracy in tool and mold making. The entire manufacturing process is dominated by the costs and time needed for mechanical machining due to the major proportion of free-forming geometries and predominant small-scale and job lot production. Beyond this, the accuracy of production defines the effort required for reworking.
Furthermore, finishing is extremely important both because of the great amount of time it requires and as a basis for subsequent breaking-in and adjustment work. Since the machining velocities to be achieved with the performance of the cutting materials used are limited, the greatest potential is to be found in enhancing the dynamic properties of the processing machine. And indeed, aligning CAM tolerances, NC control tolerances and dynamic NC control settings can save as much as 20 percent in time without even changing the machining strategy. Of course, this requires a holistic analysis of the machining process and adapting the parameters in the process to the machining job.
That means that we can make statements on the working precision of tool machines under various process and environ-mental conditions based upon a comprehensive analysis of the impact of faults along the mechanical machining process chain. They offer users and tool machine manufacturers the point of departure for improvements in producing tools or designing machine elements.