Delcam chosen as CADCAM partner by Fraunhofer Institute
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Delcam has been selected as the CADCAM partner for a project by the Fraunhofer Institute of Production Technology in Aachen, Germany, to combine prototyping and machining techniques in a new approach for the rapid manufacturing, repair and modification of tooling. The CMB (Controlled Metal Build Up) process is designed to provide a degree of hardness, surface quality and precision in the manufacture of complex geometries that "conventional" Rapid Prototyping has been unable to achieve in the past.
With the CMB process, the tool is constructed in layers formed by welding. Each layer is then machined to shape and another layer added. Since only small quantities of material need to be removed from each layer, smaller cutters can be used at high machining speeds. Deep slots and narrow corner radii can be produced without the subsequent EDM processing that would normally be required.
The major challenge that faced the project right from the start was the problem of automation. However, the Aachen team found the right partner for this task in Delcam. Basing their approach on a combination of the PowerSHAPE modelling software and the PowerMILL CAM system, the company's specialists from Birmingham managed to develop a solution that could take the 3D CAD data as a starting point, and automatically write NC programs for the paths to build up the weld and for its machining.
A major problem is that the milling data that need to be calculated do not relate directly to the final model but to each layer of weld. Thus, welding and milling data have to be defined for the entire geometry, layer by layer. The whole process must be repeated up to 100 times or more, depending on the size of the tool and the layer thickness prescribed.
Carsten Freyer, manager of the project, said, "Delcam has developed an approach that involves breaking down the geometry into layers and defining the welding and milling paths. The pure programming of the welding paths and defining of the milling cycles can today be accomplished in ten minutes. Delcam's solution is a major step in developing our process for real production."
For further information on Delcam's Power Solution software, please contact: -
Peter Dickin, Marketing Manager
Direct phone: 44 (0)121 683 1081
e-mail: marketing@delcam.com
Delcam plc
Small Heath Business Park,
Birmingham, B10 0HJ,
UK
www.delcam.co.uk
Delcam Inc.
3280 Electricity Drive
Windsor, Ont. N8W 5J1
Canada
www.delcam.com
Caption: The new machine combines welding and high-speed machining in a single machine
