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Starting situation
A geometry modification in the OP50 was necessary to optimize the forming results in a press tool to produce roof panels for trucks. The modification was initially implemented manually by experts during the tryout by applying the modification with a self-hardening rebuilding compound and modelling and optimizing it in the tryout press during test pressings. For series production with the tool, this temporary modification now had to be replaced with wear-resistant material.
Procedure
In the first step, the modification area was digitized. This was followed by CAM planning for the hard (58HRC) welding process onto the tool.
After removing the paste and cleaning the tool, the new material was applied using a mobile Picum welding system.
The pictures on the right show a photo of the system and a simulation of the application process. After welding the geometry was scanned again to ensure that sufficient material had been applied everywhere.
In the next step, the geometry was milled directly on site using the mobile Picum machining system (see image on the bottom right). The CAM planning of the tool paths was based on the previously scanned geometry of the manually modelled compound.
Advantages
The temporary geometry of the modification, which was worked out by hand by experts during the tryout, could be implemented quickly and with maximum precision directly on site. This procedure is a fine example of the productive collaboration between years of expert knowledge and "intuition" and state-of-the-art technology.
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