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Mold processing industry trends
2011-03-24 10:29:33 visited：1 From：
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The plastic materials into large, uniform shape of the components of production is the cornerstone of modern manufacturing is actually the product of each market are limited by the mold at least one out of shape. However, with the continuous development of manufacturing, mold has become increasingly complex, requiring higher and higher as strong. Technical difficulty increasing, product life cycles are getting shorter, users mold products made more requirements, such as: maintenance-free operation can be a long time, low-energy, anti-wear, easy to install replacement and with greater flexibility and so on.
Under market competition and the pressure of rising user requirements, mold manufacturers have to choose a more practical and effective way to mold, to adopt a more favorable market strategy, thus, mold has been shown the following trends.
● Globalization

The globalization of markets and the development of mold is today the most important feature of the tooling industry. Mold buyers are all over the world, and mold makers are also everywhere. The development of the globalization of industrial mold production process is simple, low precision mold processing enterprises to technology is relatively backward, low productivity in developing countries to migrate. And still remain in the United States, Europe and Japan, mold manufacturing enterprises are located in the production of high levels of mold, which is not only the technical requirements, it is the result of competition. Mold manufacturing enterprises have to face global competition in the market, this is the mold maker to pursue efficient application of technology the driving force.

● production cycle time

As we all know, in the same conditions, the users are willing to choose a shorter product delivery, because it can save more production time, so manufacturers have to do everything possible to mold to speed up the production schedule, and efforts to simplify and repeal unnecessary production processes.

● High-speed machining

Recently developed "high-speed processing" of the mold manufacturing industry had a significant impact. "High-speed processing" is very small and large step away from the feed rate to achieve, high spindle speed can usually get enough chips resistance tool. In the rough, the use of oblique small-width of the cutting tool is often a high metal removal rate, even with a small tool can achieve this effect. In many cases, after a high-speed rough machining of the workpiece surface accuracy is very close to the required level, thus eliminating the need for semi-finishing operations can be.
High-speed machining to obtain a smooth surface of the workpiece, but also saves processing time, the typical step away from 0.001in, and the sharp point only 0.00005in high, after the majority of high-speed machining of the workpiece surface is very smooth, no fitter further processing.
In the finishing process, by increasing the feed rate can be avoided as a result of the reduction step away from the duration of the extension, and subsequent polishing or grinding process of repealing or reducing it will help in the processing of surface protection.
Under normal circumstances, the machining tool to be at least 1200 per minute, the surface of feet, the spindle speed is not less than 8000r/min. After finishing the old machine tool spindle speed can reach this level, but its stability is subject to certain restrictions. At present, the machine tool manufacturers are keen on the production of high-speed machining centers designed specifically for processing. In the U.S., high-speed processing technology to reduce or eliminate fitter process is a considerable efficiency measures, this technology in Europe and Japan are also popular.

● Hard Milling

Hardening of the material processing with full mold cavity mold industry is another important trend. This is especially valuable for forging dies, because compared with other molds, forging dies often require a higher hardness. Roughing and finishing in one machine to complete a row, in the roughing process, the high spindle speed and a small tool radius cutting carried out by the formation of mildly enough torque, can be used to process up to 64RC hardness of metal materials; in finishing process, to ensure a step away from the smaller parts can be an excellent surface finish.
As the material itself has a certain hardness, the electrical discharge machining (EDM) can be reduced or all omitted. Because the material has been hard enough, without the need for further heat treatment, not only that, after the tempering heat treatment and offset the heat caused by the geometry of the deformation process carried out by grinding also is not necessary. The technology in Japan, the acclaimed, now in the United States has been widely spread in Europe of attention and positive.
High-speed machining hardened materials processing tool to put forward higher requirements. Therefore, many machine tool manufacturers to develop such a process designed special grinder. At high spindle speeds and high feed rate case, the need for light cutting tool, but a higher thermal stability and mechanical hardness is also very necessary. In such processing, high-pressure coolant is another necessary condition, but there are some dry cutting tool manufacturers a way to use the tool to prevent thermal shock. While dry cutting can also reduce environmental pollution. Most of these machine tools for machining and forging die, the small size of the mold.
Japanese Yashi Da produced for manufacturing lever forging die is hardened through a typical high-speed machining material made of. The workpiece size 164mm × 106mm × 32mm, material hardness of 60RC. The use of carbide cutters and mist coolant, the mold cavity milling time consuming 109min. Although the included hard-milling technology, the high price of these machines, but only one such machine can be completed roughing, finishing, and electrical discharge machining of the whole process, which is no doubt developed countries such as Japan, there is considerable attractive. It is noteworthy that the processing of such machines are gradually becoming more horizontal direction rather than vertical type, which is the new features.
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