How to choose the right mold processing tool?

In recent years, the development of the mold processing industry tends to be high-end, and modern machining equipment and processes represented by machining centers have placed high requirements on cutting tools.

Our helps you answer the choice of mold processing tools

In the forming and manufacturing of modern molds, due to the complex mold structure and high precision requirements, the profile characteristics and materials of different parts are quite different, so the mold milling cutters used are also different.

Mold processing procedures can be divided into rough machining, semi-finishing and finishing, and sometimes even super finishing. Indexable tools are generally used for roughing and semi-finishing processes, and integral tools are used for finishing processes.

  • Rough milling

In pursuit of the maximum material removal rate per unit time, an end mill should be used to mill the contour surface layer by layer according to the margin given by the processed surface, which is highly efficient. Small molds are mostly processed with integral end mills. Large molds are processed by machine-clamped end mills with indexable inserts in consideration of their economy and processing efficiency. There are mainly R-shaped round inserts and square shoulder milling inserts. Face milling blades, etc.

  • Semi-finish milling

To make the machined surface closer to the theoretical curved surface, a ball-end milling cutter can be used, generally leaving a machining allowance of about 0.5 mm for the finishing process.

  • Finishing

Finally, the theoretical surface is processed. Generally, an integral end mill or a ball end mill is used. When using a ball-end milling cutter to finish machining a curved surface, the line cutting method is generally used to appropriately increase the spindle speed, select an appropriate turning point, and reduce the tool mark caused by pause and vibration.

  • Avoid vertical cutting

A good way is to feed the tool diagonally downward, and then use the side edge to cut laterally after reaching a certain depth. When milling the groove surface, the process hole can be pre-drilled for cutting.In milling curved parts, if abnormalities such as poor heat treatment, cracks, and uneven organization of the parts are found, the processing should be stopped in time to avoid wasting man-hours.

The machine tool, fixtures, and tools should be properly checked before starting milling every time, so as to avoid failures in the middle, affecting the machining accuracy, and even causing waste.

When milling the mold cavity, the repair allowance should be properly controlled according to the roughness of the machined surface. For parts that are more difficult to mill, you should leave more trimming allowance; for flat, right-angle grooves and other easy-to-process parts, you should try to reduce the surface roughness value and reduce the number of repairs.

In mold processing and manufacturing, the selection of tools needs to be comprehensively considered from several aspects such as workpiece material, occasional working conditions, cutting stability, cost, productivity, and processing accuracy. Only a reasonable choice of tools can improve processing quality and processing efficiency, meet product aesthetics and functional requirements, and improve mold processing technology.

Write a Comment