At present, plastic molds are becoming increasingly sophisticated, with more complex structures and higher precision requirements. The number of molds needed has reached and even exceeded 800,000 units. Foreign plastic mold manufacturers are using mold steels with higher hardness, some exceeding HRC 64, while delivery times are getting shorter. These market trends have placed significant pressure on mold manufacturers. However, the emergence of high-speed milling technology has opened up new opportunities, especially in the production of small and medium-sized precision plastic molds.
High-speed cutting not only reduces machine processing time but also minimizes overall process time. With higher cutting speeds, less material is left for finishing, and tool paths are denser with shallower cuts. For free-form surfaces, cutting depths typically range from 0.02 to 0.1 mm, and for tools with diameters between 0.3 and 0.8 mm, the depth of cut can be as low as 0.008 to 0.02 mm. This fine and tight tool path improves surface finish and reduces the need for manual polishing by up to 60% to 100%, as well as decreases EDM (electrical discharge machining) time. Many foreign mold makers have already seen these benefits.
High-speed milling also allows for the machining of thin-walled ribs and small-radius features that were previously difficult to achieve. Thanks to improved spindle speed, dynamic balance, and machine stability, high-speed cutting can be performed with minimal force, enabling the processing of walls as thin as 0.1 mm. Even with materials up to HRC 54, a 0.3 mm diameter tool can be used effectively. This reduces the number of electrodes needed and shortens EDM time significantly.
Before high-speed milling, engraving machines were used to make electrodes, but this method was inefficient, prone to tool breakage, and resulted in poor surface finish. It could not meet the high standards required by international companies. High-speed milling has dramatically improved both the quality and efficiency of electrode production.
In terms of part accuracy, high-speed milling generates less heat, which is carried away by the chips rather than accumulating in the workpiece. This results in less thermal deformation and better machining accuracy. Additionally, high-precision electrodes produced through high-speed milling require little or no polishing, ensuring consistent and accurate mold manufacturing.
High-speed milling also enhances electrode processing and improves EDM efficiency. It enables faster cutting of copper and graphite electrodes, with much higher material removal rates compared to traditional methods. Finishing with high-speed light cutting produces smoother electrodes, reducing or eliminating the need for polishing. When working with graphite, PCD-coated tools significantly reduce wear, making high-speed milling feasible.
In EDM processes, high-speed milled electrodes provide uniform discharge areas, better surface contact, and improved control over the discharge gap, increasing efficiency. Smaller tools also reduce machining allowances, allowing for the elimination of coarse electrodes and reducing the total number of electrodes needed, thus saving time in the EDM process. Overall, high-speed milling is transforming the mold manufacturing industry, offering greater efficiency, precision, and flexibility.
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