In the United States, Germany and Japan and other industrialized countries, the mold industry in recent years engaged in a massive technological revolution, which is gradually replaced by high-speed cutting machine tools,glue stick processing equipment, the mold cavity for high precision machining. These tools include a variety of high-speed CNC milling machines, machining centers.
Currently in the process of mold manufacturing, mainly in general machining and EDM processing. General machining the mold cavity before the heat treatment are generally rough, semi-finishing and finishing,glue gun and then grinding, polishing, time-consuming and laborious. EDM is a machining after annealing and then heat treatment, EDM, and finally through the grinding, polishing.
With the upgrading of consumer products accelerates, the mold production efficiency and manufacturing quality higher and higher requirements of EDM tooling and quality production inefficiencies gradually exposed the shortcomings of instability. To shorten the manufacturing cycle and reduce costs, to be extensive use of advanced machining technology. Advanced manufacturing technology on behalf of high-speed cutting technologies, to meet the requirements of modern tooling and features.
High-speed cutting technology for the processing of the mold main advantage:
(1) significantly improve the processing efficiency, not only high speed machine tools, feed faster, and a rough finish can be completed, greatly improve the efficiency of production, combined with numerical control technology, mold manufacturing cycle can be reduced by about 40%.
(2) high-speed machining electrode mold do not need, do not need to follow the grinding and polishing, but also easy to implement process automation to improve the speed of mold development.
(3) can be processed using high-speed cutting of hardened steel technology, and obtain high surface quality, surface roughness less than Ra0.6μm, instead of grinding to obtain the milling processing effects, not only saves a lot of time, but also improve surface quality.
In order to achieve the relevant parts of the mold cavity and its high-speed machining, the machine need to have the following characteristics:
(1) large load-bearing and high rigidity which is due to the direction of the mold is the large-scale development, processing equipment must have sufficient size and large working stroke of the table with them to adapt. Now, a few tons to hundreds of tons of mold are common, requiring a large machine can bear the weight of the work surface. Mold materials have high strength and hardness, coupled often with a large elongation processing small-diameter end mill mold cavity, the process prone to flutter. To ensure the machining accuracy and surface quality, high-speed machine tools for mold must have a high dynamic and static stiffness, in order to improve the positioning accuracy of machine tools, tracking precision and anti-vibration capability.
(2) high speed and direction is the development of high-power high-speed machining, high speed milling in the mold processing has shown great advantages. In order to adapt the processing of the mold cavity surface, the radius of the tool should be less than the minimum circle radius of the cavity surface, so the tool and the workpiece during processing occurred "interference." As the tool diameter is small, thus requiring very high spindle speed, high-speed machine tool spindle speed abroad has reached 40000 ~ 100000r/min, rapid traverse speeds of up to 30000 ~ 60000min. Cavity and other parts of the mold parts thick, often finishing a fixture in the workpiece and, therefore, spindle power to large, medium-size molds milling and machining center spindle power often 10 ~ 40kW, some even higher.
(3) to multi-axis integrated cavity deep and good cutting ability of the mold cavity to complex multi-space 6 and the grooves of the surface composition, and many die with a deep cavity. In order to achieve 3D surface accuracy, high speed and high stability of the processing needs of multi-axis machine, and deep cavity has a good comprehensive cutting capacity. Five-axis machining center can be used, in addition to the three coordinates of linear motion, there are two rotating coordinate the feed movement. Multi-axis milling head or the table can feed a continuous rotation, which applies to processing of the cavity surface of the mold with complex parts.
Mold compound processing is one of the development. Although the processing center has been able to many complex machining processes on a single machine to achieve, but it still can not fully meet the mold, the mechanical processing and electrical, chemical, ultrasonic processing method of compound different principles, both the technological characteristics of two or more combined machining mold in the future will have broad prospects.