**Application of Delcam Software in the Production of Car Cover Molds (Part I)**
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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
*250*250 was created on 2017/12/25* var cpro_id = 'u3171089'; ### I. Introduction FAW Mold Manufacturing Co., Ltd. was established in 1954 and has been supplying body molds and technical support to FAW and over 30 manufacturers across the country for more than 48 years. In the mid-1990s, with the production of trucks, the company underwent significant changes in mold manufacturing. Over the past three years, the company has made substantial investments in equipment and technological upgrades, introducing more than ten high-speed CNC milling machines from abroad. This has placed the company at the forefront of domestic mold processing capabilities. Previously, the company relied on EUCLID software for programming, but due to its outdated development and limited functionality, it failed to meet the evolving needs of production. After thorough research and testing of leading global CAD/CAM software, the company selected Delcam’s PowerSHAPE and PowerMILL series as its primary programming tools. In just one year, the company successfully used this software to produce over 200 sets of molds for Chery Automobile Co., Ltd. and Mazda Automobile Co., including a large number of masking molds. The results were impressive: programming efficiency increased by over 50%, machining efficiency improved by more than 30%, and tool life also rose by over 30%. Additionally, Delcam software played a key role in the localization of high-end car molds, such as the full-side mold of the Jetta model produced by FAW Volkswagen. This mold is over 5 meters long and 3 meters wide, with complex geometry. Previously imported from Germany, it cost about 3 million RMB, but after localization by our company, the cost dropped to around 1 million RMB, saving nearly two-thirds of the budget. Currently, only our company can manufacture such high-precision, complex molds. The following section will provide an analysis of our successful experience in producing car cover parts using Delcam software, focusing on modules like PowerSHAPE and PowerMILL, along with their auxiliary functions. --- ### II. Reverse Engineering of the Full-Side Mold of the Jetta Car Some of the full-side molds of the Jetta car were created using reverse engineering techniques and processed through PowerSHAPE. Delcam's intelligent SHA and intelligent toolbar features greatly enhanced our workflow. Its powerful surface modeling and modification capabilities are particularly suitable for repairing and reconstructing complex geometries. --- ### III. CNC Machining Process The CAD model generated in the PowerSHAPE module is directly transferred to PowerMILL for NC programming. Based on the characteristics of the side wall model, the machining process 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 processing intelligently calculates the stock material and optimizes the tool path. The racing line roughing strategy, unique to PowerMILL, maximizes rounded corners and smooths sharp edges. It also uses cycloidal machining in recessed areas, which suits high-speed machining needs. Compared to parallel processing, layered processing saved a significant amount of time. **(2) Pocketing After Roughing** This step removes unprocessed material at the concave corners of the rough or semi-finished part, ensuring uniform cutting conditions for the next process. Since we used large tools for roughing, there were still residual materials in the groove areas. Therefore, we added a pocketing step before finishing. We also used a Ф20 ball-end mill during this phase. The chosen strategy was PowerMILL’s knowledge-based layered pocketing, which intelligently identifies unprocessed areas and optimizes the remaining tool paths. **(3) Semi-Finishing** After roughing, a step-like margin is left on the surface, which provides a uniform allowance for the final finish. We used PowerMILL’s shoal method, selecting a Ф30 ball-end mill with a 45° angle as the boundary. The software automatically divides the model into flat and steep areas. For flat areas, we used parallel processing with arc connections, while for steep areas, contour processing was applied. Rounded smoothing was used at sharp corners, and spiral feed methods were employed, all of which align with high-speed machining requirements. This approach significantly improved our machining efficiency and extended tool life. **(4) Finishing Preparation** Before the final finishing, we used PowerMILL’s pen-type rooting strategy to remove any remaining unprocessed material at the concave corners, greatly enhancing the finishing quality. --- ### Related Bearings Knowledge - Classification of ceramic bearings - Diagnosis of rolling bearings - Oscillation analysis and strength improvements in imported bearings - Latest learning of bearing shortcuts list - Understanding bearings --- This article links to http:// Please indicate the bearing network: http:// Previous: How to choose the appropriate type of rolling bearing Next: The bearing of diesel engine hydraulic transmission system
*250*250 was created on 2017/12/25* var cpro_id = 'u3171089'; ### I. Introduction FAW Mold Manufacturing Co., Ltd. was established in 1954 and has been supplying body molds and technical support to FAW and over 30 manufacturers across the country for more than 48 years. In the mid-1990s, with the production of trucks, the company underwent significant changes in mold manufacturing. Over the past three years, the company has made substantial investments in equipment and technological upgrades, introducing more than ten high-speed CNC milling machines from abroad. This has placed the company at the forefront of domestic mold processing capabilities. Previously, the company relied on EUCLID software for programming, but due to its outdated development and limited functionality, it failed to meet the evolving needs of production. After thorough research and testing of leading global CAD/CAM software, the company selected Delcam’s PowerSHAPE and PowerMILL series as its primary programming tools. In just one year, the company successfully used this software to produce over 200 sets of molds for Chery Automobile Co., Ltd. and Mazda Automobile Co., including a large number of masking molds. The results were impressive: programming efficiency increased by over 50%, machining efficiency improved by more than 30%, and tool life also rose by over 30%. Additionally, Delcam software played a key role in the localization of high-end car molds, such as the full-side mold of the Jetta model produced by FAW Volkswagen. This mold is over 5 meters long and 3 meters wide, with complex geometry. Previously imported from Germany, it cost about 3 million RMB, but after localization by our company, the cost dropped to around 1 million RMB, saving nearly two-thirds of the budget. Currently, only our company can manufacture such high-precision, complex molds. The following section will provide an analysis of our successful experience in producing car cover parts using Delcam software, focusing on modules like PowerSHAPE and PowerMILL, along with their auxiliary functions. --- ### II. Reverse Engineering of the Full-Side Mold of the Jetta Car Some of the full-side molds of the Jetta car were created using reverse engineering techniques and processed through PowerSHAPE. Delcam's intelligent SHA and intelligent toolbar features greatly enhanced our workflow. Its powerful surface modeling and modification capabilities are particularly suitable for repairing and reconstructing complex geometries. --- ### III. CNC Machining Process The CAD model generated in the PowerSHAPE module is directly transferred to PowerMILL for NC programming. Based on the characteristics of the side wall model, the machining process 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 processing intelligently calculates the stock material and optimizes the tool path. The racing line roughing strategy, unique to PowerMILL, maximizes rounded corners and smooths sharp edges. It also uses cycloidal machining in recessed areas, which suits high-speed machining needs. Compared to parallel processing, layered processing saved a significant amount of time. **(2) Pocketing After Roughing** This step removes unprocessed material at the concave corners of the rough or semi-finished part, ensuring uniform cutting conditions for the next process. Since we used large tools for roughing, there were still residual materials in the groove areas. Therefore, we added a pocketing step before finishing. We also used a Ф20 ball-end mill during this phase. The chosen strategy was PowerMILL’s knowledge-based layered pocketing, which intelligently identifies unprocessed areas and optimizes the remaining tool paths. **(3) Semi-Finishing** After roughing, a step-like margin is left on the surface, which provides a uniform allowance for the final finish. We used PowerMILL’s shoal method, selecting a Ф30 ball-end mill with a 45° angle as the boundary. The software automatically divides the model into flat and steep areas. For flat areas, we used parallel processing with arc connections, while for steep areas, contour processing was applied. Rounded smoothing was used at sharp corners, and spiral feed methods were employed, all of which align with high-speed machining requirements. This approach significantly improved our machining efficiency and extended tool life. **(4) Finishing Preparation** Before the final finishing, we used PowerMILL’s pen-type rooting strategy to remove any remaining unprocessed material at the concave corners, greatly enhancing the finishing quality. --- ### Related Bearings Knowledge - Classification of ceramic bearings - Diagnosis of rolling bearings - Oscillation analysis and strength improvements in imported bearings - Latest learning of bearing shortcuts list - Understanding bearings --- This article links to http:// Please indicate the bearing network: http:// Previous: How to choose the appropriate type of rolling bearing Next: The bearing of diesel engine hydraulic transmission system
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