To provide the high-performance results demanded in today’s moldmaking, many indexable-insert ballnose endmills use PVD-coated, precision-ground, micrograin- carbide inserts. Experience shows that such inserts perform best with sharp edges, which represents a departure from the conventional wisdom that extra-strong edges are required to stand up to hardened materials at very high feedrates. […]
In addition to modular endmilling systems specifically designed for mold-making and other copymilling applications, general indexable-insert endmilling systems are available that include components for high-speed/high-feed finishing of molds and dies. […]
Both solid-carbide and small indexable-insert ballnose endmills are capable of the speeds and feeds required for high-speed finishing of molds. Moldmakers should keep in mind, however, that the indexable-insert tools offer important cost advantages – starting with a much lower replacement cost and no regrinding. […]
When justifying the investment, it is important to complete an accurate estimate of the potential cost savings for automating an area. Robotic automation offers many direct benefits to the bottom line of the manufacturing operation. Replacing manual operations reduces obvious factors like labor cost including overtime, benefits and taxes. […]
Rule 1: Mold tolerances become more critical.As parts get smaller, any miscalculations have a significantly greater impact. When requesting a micro mold, aim for 10 percent part tolerances, as opposed to the 25 to 50 percent level commonly seen in macro molds, […]
High Energy Applied Technology (H.E.A.T.) was developed to address the need for high-speed cutting of wire EDM applications where good, sealed flushing cannot be achieved, while at the same time providing high accuracy, unparalleled part straightness, and good surface finishes. The desire to be able to use the most common EDM wires in today’s market [...]
To find the best process you must find the bottlenecks and move them to the beginning of the process. Now finding all the bottlenecks and addressing them appropriately is a challenge, but the answer is so simple: standardize all processes. […]
The changes over the past 15 years have been severe and the confusion over how to conduct business in these uncertain times has prevented many moldmaking businesses from evolving to counteract those challenges. But change can be managed effectively—even now. Small- and medium-sized manufacturers (SMMs) have options and resources available to effect the changes necessary [...]
A moldmaker likes a challenge, and that is what was received when first-rate mold solution co, ltd was approached. The molder had been manufacturing a product for some time and had many molds used for its production, but now there was a desire to alter the molds in order to reduce the part weight due [...]
In moldmaking applications, H.E.A.T. can be used very effectively to cut inserts, core pins and insert pockets that contain contours and changing surface thicknesses. […]