Starting situation: To optimize the forming results in a press tool for the production of roof sheets for trucks, a geometry modification in the OP50 was necessary. The modification was initially carried out manually in the course of the tryout, by applying the modification with self-hardening plasticine and modeling and optimizing it by experts in the tryout press during test pressings. For series production with the mold, this temporary modification now had to be replaced by wear-resistant material.
Procedure: In the first step, the area of the modification was digitized. This was followed by CAM planning of the hard (58HRC) weld onto the tool. After removing the paste and cleaning the tool, the new material was applied using a mobile Picum welding system. The pictures below show a photo of the equipment as well as an illustration of the simulation of the application process. After welding the geometry was scanned again to ensure that there was
to ensure that sufficient material had been applied everywhere. The next step was to mill the geometry with the Picum mobile machining system directly on site (see picture below). CAM planning of the tool paths was based on the previously scanned geometry of the manually molded clay.
Advantages: The temporary geometry of the modification, which was worked out by hand by experts in the course of the tryout, could be implemented quickly and with maximum accuracy directly on site. This procedure shows a fine example of productive cooperation between years of expert knowledge and “flair” with state-of-the-art technology.