Characteristics of mold high-speed milling machining center

In order to achieve high-speed processing of mold cavities and related parts, high-speed mold milling machine tools need to have the following characteristics:

1. Large load-bearing and high rigidity

This is because molds are developing in a large-scale direction, and processing equipment must have a large enough table size and working stroke to adapt. Nowadays, molds ranging from several tons to dozens of tons are very common, requiring the machine tool work surface to bear heavy weight. The strength and hardness of the mold material are very high, and small-diameter end mills with large elongations are often used to process the mold cavity, so chatter is prone to occur during the machining process. In order to ensure the processing accuracy and surface quality of parts, high-speed machine tools used for mold manufacturing must have high dynamic and static stiffness to improve the positioning accuracy, tracking accuracy and vibration resistance of the machine tool.

2. High speed and high power

High-speed machining is the development direction, and high-speed milling has shown great advantages in mold processing. In order to adapt to the processing of the mold cavity surface, the radius of the tool should be smaller than the minimum circumferential radius of the cavity surface to avoid “interference” between the tool and the workpiece during the processing process. Due to the small diameter of the tool, the spindle speed is required to be very high. The spindle speed of foreign high-speed processing machine tools has reached 40,000~100,000r/min, and the rapid feed speed can reach 30,000~60,000min. Rough and finish machining of the cavity and other parts of the mold are often completed in one clamping of the workpiece, so the spindle power must be high. The spindle power of medium-sized mold milling machines and machining centers is often 10~40kW, and some are even higher.

3. Capable of multi-axis linkage and good comprehensive cutting capabilities for deep holes

Mold cavities are mostly composed of complex spatial surfaces and grooves, and many molds have deep cavities. In order to achieve high-precision, high-speed and high-stability processing of 3D curved surfaces, machine tools require multi-axis linkage and good comprehensive cutting capabilities for deep holes. A five-axis linkage machining center can be used. In addition to the linear motion of three coordinates, there are also feed motions of two rotary coordinates. The milling head or worktable can perform continuous rotary feed in multi-axis linkage, making it suitable for processing mold parts with complex cavity surfaces.

Composite processing is one of the development directions of mold processing. Although the machining center has been able to combine many machining processes on one machine tool, it is still not fully suitable for mold processing. It combines machining with different principle processing methods such as electricity, chemistry, ultrasonic and so on, and has the characteristics of two or more processes. Composite processing will have broad prospects in future mold manufacturing.

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