Sep 16, 2011

Tebis presents complete turning and milling in one setup

Accuracy and deadlines can frequently only be met with machining if the component is made with as few machines and setups as possible. Tebis supports this complete machining strategy with a new module for turning.

The requirements for the machining of components are growing and becoming ever more complex. The required precision levels and the delivery deadlines leave less room for error for manufacturers. New setups or even a change of machine costs precious time and accuracy. The answer to these challenges is modern machining centers that enable complete machining – from milling, to drilling, to turning – in no more than two setups.

The new Tebis module for turning will be presented at the EMO 2011 in Hanover. This module integrates seamlessly all these different types of machining in one CAD/CAM system, just as they are combined in one machining center. With Tebis this means that the machines can now fully utilize their productivity advantage. The Tebis technology, with the virtual replication of the entire manufacturing environment, ensures that interruptions are eliminated in the manufacturing process once the component is set up.

At EMO 2011, a pump case with a machining volume of nearly 54 % of the blank dimensions of Ø 450 x 430 mm will be used as a demonstration part. In order to show the geometry and machining as realistically as possible, our trade show preparations were supported by our customer Berghoff GmbH + Co. KG, in Drolshagen, Germany. The component utilizes all functions of the new Tebis software for the turning of contours, grooves and threads, as well as side-face drilling – even off-center. In addition, considerable conventional milling and drilling is required, resulting in more than 90 machining operations, requiring 29 different tools.

The machine used – a Deckel Maho DMC 80 FD – is integrated in Tebis as a 1:1 virtual model. Therefore, all of the machine's capabilities can be taken into account during programming. Prior to the NC output, the Tebis Simulator checks all movements of the machine for collision and range of travel within the available machining area. This makes sure the entire NC program for all machining tasks can then run in a virtual world without interruption.

The component then needs to be set up on the machine, and the availability of the correct tools is verified. These setup requirements originate in the virtual world of Tebis. This is done before the machine is started. The NC program will then run without interruption until the unclamping of the finished component. With the assurance of the Tebis virtual world, even complex components are made on time and with the required accuracy. The investment in the expensive machinery quickly pays for itself.