Software can help compensate for excessive erosion during taper cutting with wire EDM. Wall straightness or angle accuracy often present a challenge to the machine operator when he or she is attempting to wire EDM taper angles. Several factors within the EDM process affect angle accuracy. These include, but are not limited to, temperature, machine [...]
Incorporating multiple-gate nozzles means smaller molds, small presses, a balanced fill rate, reduced residence time, temperature control and design flexibility. […]
Careful consideration of the entire machining system will improve milling of hardened steels. To maximize productivity and reliability, mold shops often machine a large portion of their products from hardened steels. Historically, hardened steels have been rough milled at low feeds and speeds, with large depths of cut and stepovers. […]
For large injection-molded parts, a servo-driven valve gate system can improve surface finish and part performance. The art of sequential molding has proven to be a beneficial process in many markets. Automotive suppliers are one of the largest users of this technology, especially for the production of plastic parts with Class A surface finishes. Sequential [...]
Mold builders and molders should carefully consider hot runner selection, as it dramatically impacts an injection molding system’s speed, quality and uptime. […]
Molds have to be cleaned. There’s no way to avoid it. But what if the mold could clean itself, eliminating the negative impact of manual maintenance on productivity? […]
The high-strength aluminum alloys available today are feasible alternatives to steel for tooling. Originally used primarily for the production of prototypes because of its lower cost, aluminum offers several other advantages that make it a viable option for production molds. […]
If you opt to use aluminum for your next mold project, it’s important to select the appropriate aluminum alloy. Alloys are created when elements including copper, magnesium and zinc are added to the base aluminum. Each added element contributes individual beneficial properties that will improve the aluminum. […]
Different aluminum alloys require differing welding wires in order for successful welding to be achieved. Characteristics of the wire should match those of the specific alloy on which it will be welded, and the wire’s color-matching ability, strength and effect on HAZ should also be considered. Additionally, the welding wire must have a melting temperature [...]
Once the proper wire has been selected, focus must shift to the proper technique for mold alloy to be welded. This is the largest contributor to a successful weld repair. A proper technique involves more than the actual welding; it must also take into account ambient conditions and preheating of the material, which will remove [...]