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In the die-build environment, machining centers generally are limited to machining contours, complex or large parts, such as stripper plates. This type of machining represents only 10% to 20% of die machining.
Typically, 80% to 90% of die machining is the machining of simple details, which are square or rectangular in shape. They may require squaring, chamfering, drilling, tapping, counterboring and reaming. These details have been machined with a manual mill, because programming and setup time for a machining center requires as much or more time than with a manual mill.
For example, to machine a die detail, the operator runs through the same procedures and setups on a machining center to square a block and machine it, as with a manual mill. There is little if any time advantage with a machining center and the cost is much higher.
Typically, CNC programming takes much longer than machining the part on a manual mill. As a result, a machining center may actually increase die build costs.
Revcam designed a system that treats machining of die details as a production process. By minimizing setup time and automating programming, machining costs can be reduced by up to 68%.
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