Impressive Cycle Time Optimization in Stamping Die Machining

Stamping dies are one of the most time consuming, hard to machine components of the automotive industry. A typical machining strategy for contour surface is to use ball type cutters removing material at varying depths of cut. Long overhangs from the spindle nose puts excessive loading on the tool, and spindle. In addition, constantly varying part geometry and depths of cut make it extremely difficult to maintain a proper chip load on the cutting edges. As a result, process planners typically choose conservative cutting conditions because an error in part program is not affordable when it comes to machining small quantities. 



The case study below sets a good example how a legacy part program for a stamping die can be effectively optimized. Using the same equipment, tooling, and part programs, MACHpro virtually analyzed the machining process, successfully optimized feed rates and generated a new NC program that the machine was running in the video below. The result was an absolute success with an average of 25% reduction in the overall cycle time while the chip load maintained, insert breakage was avoided, and spindle was used at its maximum torque.


Machining of a Stamping Die
Insert Breakage: Eliminated
Spindle Overload: Eliminated
Machining Time: Reduced by 25%
Cost Savings: 40%
Additional Cost to the Manufacturer: Zero!

Constant feed rates in the original program inevitably resulted in chip thinning and failure of inserts, where "optimized" program by MACHpro corrected chip control and resulted in smoother high performance machining.