**Application of Delcam Software in the Production of Car Cover Molds (Part I)**
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**I. Introduction**
FAW Mold Manufacturing Co., Ltd. was established in 1954 and has provided body molds and technical support to FAW and over 30 manufacturers across the country for nearly 48 years. In the mid-1990s, when trucks were being produced, the company underwent significant changes in its mold manufacturing process. Over the past three years, it has further increased its investment in equipment and technology, introducing more than ten large-scale high-speed CNC milling machines from abroad. This has placed our company at the forefront of the domestic industry in terms of processing capabilities.
Previously, we mainly used EUCLID software for programming, but due to its lack of updates and limited functionality, it failed to meet our production needs. After thorough testing of leading CAD/CAM software worldwide, we chose DELCAM’s PowerSHAPE and PowerMILL series as our primary programming tools.
In the past year, we have successfully processed over 200 sets of molds for Chery Automobile Co., Ltd., as well as many others for Mazda. These include masking molds that make up the majority of our work. Since implementing DELCAM software, our programming efficiency has improved by over 50%, processing power by more than 30%, and tool life has also increased by over 30%. Additionally, we have completed the localization of several high-end car molds, such as the full side mold of the Jetta model. Previously, importing such a mold from Germany would cost around 3 million RMB, but after localization, the cost dropped to about 1 million RMB, saving approximately two-thirds of the budget. Currently, only our company can produce such high-precision, complex molds for high-end vehicles.
The following is a mock-up of the full side mold of the Jetta car, which will be used to analyze some of our successful experiences in producing car cover parts using DELCAM software. The software includes modules like PowerSHAPE and PowerMILL, along with auxiliary functions.
**II. Reverse Engineering of the Full Side Mold of the Jetta**
Some of the molds were made using reverse engineering methods and processed through PowerSHAPE. DELCAM's SHASHA software and intelligent toolbar significantly improved our workflow. Its strong surface modeling and modification capabilities are especially suitable for complex mold design and repair.
**III. CNC Machining Process**
The CAD model generated in the PowerSHAPE module is directly transferred to PowerMILL for NC machining. Based on the characteristics of the side wall model, the machining path is designed as follows:
(1) **Roughing**: Due to the large amount of material to be removed, we used a Ф50R6 ball-end mill for layered processing. PowerMILL’s layered strategy intelligently calculates the blank material and optimizes the tool path. The racing line roughing strategy maximizes rounded corners and smooths sharp edges, while using cycloidal machining in recessed areas. These techniques align with high-speed machining requirements. Testing showed that this method saved a lot of time compared to parallel processing.
(2) **Roughing Post-Processing**: This step removes unprocessed data at concave corners, ensuring uniformity for the next process. We used Ф20 ball-end cutters to clear residual material. PowerMILL’s knowledge-based root processing identifies unprocessed areas and optimizes the remaining tool path.
(3) **Semi-Finishing**: After roughing, a step-like margin remains. We used Ф30 ball-end cutters with a 45° angle boundary. PowerMILL divides the model into flat and steep areas, applying parallel and contour strategies accordingly. Rounded smoothing and spiral feed methods were used to improve stability and speed.
(4) **Finishing Preparation**: Using PowerMILL’s pen-type rooting strategy, we removed residual material at concave corners, greatly improving finishing efficiency.
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Application of Delcam Software in the Production of Car Cover Molds (Part I)
Source: China Bearing Network | Time: 2013-02-11
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