WorkNC provides economic 5-axis machining for Heck & Becker

The German company of Heck & Becker was founded in 1936 and now has around 200 employees at its factory in Dautphetal. Its customers include almost all leading European motor vehicle manufacturers, their suppliers and leading companies in the machine construction and foundry sectors. The company is well known for developing and manufacturing large moulds for aluminium and magnesium die casting. These can weigh up to 80 tonnes and are developed and manufactured for the foundry industry. Heck & Becker is also a leader in the field of forging technology, where it produces complex tools and undertakes highly skilled machining tasks.

<< For the gear cover mould we achieved a reduction of approximately 30% in the number of milling paths. >>
Hartmut Lorenz, Programming Manager, Heck & Becker

Even though simultaneous 5-axis milling is considered to be technologically superior, Hartmut Lorenz, programming manager at Heck & Becker, realises that it is not always the most economically efficient solution, "Initially, opinions were divided in our company with regard to efficiency. After the induction period and following our experience of the savings in time and costs, things are different." For example, the process is not used for workpieces requiring many table and axis movements and long processing distances, with all axes engaged simultaneously. Hartmut Lorenz believes that the range of workpieces must be analysed before investment in 5-axis technology, “We use 5-axis milling for around ten percent of our range of workpieces, which is quite a lot. If the range of workpieces is suitable, then substantial savings can be expected.”

Heck & Becker was already impressed with its experience of the 3-axis version of WorkNC, so it was keen to implement the new WorkNC Auto 5 module, which it has been using since the beginning of 2004. The software considerably reduces programming effort by taking normal 3-axis movements and automatically converting them into 5-axis movements. At the same time, priority is given to collision avoidance. Werner Mller, Sales Manager for Sescoi, Neu-Isenburg explained, “Auto 5 calculates the points where collisions will occur between the toolholder and the machine, automatically avoiding these by inserting 5-axis movements.” He continued, “WorkNC is unique in its ability to detect and avoid collisions simultaneously - modifying the machining strategy to produce a safe toolpath.”

For a deep gear cover mould, manufactured by Heck & Becker, the shape is easy to reach from above. However, machining in 3- axis would have required a completely impractical 600mm long tool. Programming with 3+2 axis would have been a possibility, cutting from different directions, but this would have required a great deal of programming input and may have resulted in steps in the workpiece caused by tool wear between the different operations. By using WorkNC Auto 5, steady and harmonious running was achieved. The tool was pre angled, and ran in 4-axis mode until a collision point was detected. At these points, the C-axis rotated, enabling cutting to continue without incident. Hartmut Lorenz added, “For the gear cover mould we achieved a reduction of approximately 30% in the number of milling paths.”

On many parts, Heck & Becker previously employed 3+2 programming to enable it to machine undercut conditions. To produce successful results required many toolpaths, and because it was difficult to understand exactly what was happening during some of the very small cuts, these would need to be closely examined through the graphics interface. Werner M ller said, “With WorkNC Auto 5, programming is far simpler. In addition Heck & Becker is reporting savings of 15% on machining times and costs.”

The company now uses spherical cutters on some of its moulds. The tool can machine around the complete workpiece, making face machining unnecessary. Consequently there are no transitions or unmatched surfaces, producing a reduction in reworking of approximately 15%. Equally important to Hartmut Lorenz is the fact there is just one integrated programme running and that resetting between multiple programmes is eliminated.

Hartmut Lorenz appreciates that successful implementation of 5-axis machining requires dedication and collaboration, "Sescoi provided a four-day training course, and worked closely with us to introduce the new technology as quickly as possible.” Heck & Becker is a pioneer in the implementation of 5- axis machining and has closely studied its economic efficiency. It has been impressed by WorkNC’s 5-axis capability, and has achieved substantial savings of time and costs as well as measurable increases in quality.