Efficient Mold Manufacturing

Efficient Mold Manufacturing
An Introduction to Makino Technology for the Die Mold Industry

Makino India Pvt. Ltd

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Recent Trend for Mold Manufacturing
High Accuracy/Speed Micro/Fine milling Process intensive

Hard Small Deep Accurate

Automation Systematic
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Requests to the Machine Tool Builder
Mold Manufacturing Process
Product Design Mold Design NC data Machining Polishing+Assembling

Multi-Process Milling/EDM/Grinding High-Quality NC data supply on time Reduce machining time Reduce processes High-efficiency surface Automation

By workers Reduce time

Requests

HighQuality/Easy CAM system

High-Speed High-Accuracy Automation Easy Operation
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High Speed Milling can
Eliminate EDM, in many cases, by
–Direct machining of hardened steel –Use of very small cutters –Use of high L/D ratios

Connecting Rod Forging Die Remote Control Cavity
Material: AK80 Dimension: 110 x 60 x 15mm Machining Time: 3 hr 30min Minimum Cutter size: 0.6mm Dia BEM Material: SKD61 (48Hrc) Dimension : 260×110×25 mm × × Machining Time: 2 hr 34min

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High Speed Milling can
Produce better machined surface, thereby reduce the need for polishing

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High Speed milling can
Produce EDM Electrodes more efficiently
–Shortest machining time –High quality surface and shape accuracy –Consistent quality for repetitive electrodes

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Components of HSM

HSM Capable Machine Tool Cutting Tool

Controller

HSM capable Programming CAM System Know-how

HSM - High Efficiency Milling

“It is only as good as the weakest link”

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Key Technologies in a High Speed Machine

Spindle Technology

Controller Technology

High Speed Machine

Mechanical Structure

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Common Sense
Increase feed-rate, Accuracy comes down For High-Precision machining, Feed-rate should be slow・・

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Control Technology
At Corner
Error Error Programmed path Actual path

Programmed path Actual path

Round cutting
ΔＲ Ｒ Programmed path Actual path

Step on around cutting

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GI.3／SuperGI.3／SuperGI.4
GI Control Recognizing of Complicated shape（Geometric）, Actual tool path is controlled as the most Suitable and Intelligent • Smooth movement control along programmed path • High-response servo • High-rigidity machine

Improve Machining Accuracy Improve Surface Quality Improve Machining Time
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High-Quality Spindle Mini. Run-out High-Speed
Fine/small machining

High-Rigidity
Cutting capability with low rev.

Mirror surface

Min. Vibration
2.0 1.8
Ｘ軸方向 Ｙ軸方向 Ｚ軸方向

High-Accuracy
Min. step for machining

Vibration ( m)

1.6 1.4 1.2 1.0 0.8 0.6 0.4 0.2 0.0 0

Spindle vibration

5000

10000

15000

20000

Spindle rev. (min-1)

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Spindle Design Features
• Field-proven design
– Built in motor type spindle – Very low spindle vibration – Hybrid Bearing (Ceramic ball)

• Oilmatic Chiller unit for the Spindle • Performance Characteristics
– Jacket Cooling (Spindle & Motor) – Controls spindle growth – BT #40 taper/120 to 12,000 RPM – 22 kW duty rated – 18 kW continuous rated – 117 Nm duty rated torque

• 4 nozzles circulating around the spindle

– Ensure maximum coverage to the cutting zone

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Spindle Core Cooling・Jacket Cooling
Spindle Lubricant Temperature Controller
IN OUT OUT

IN OUT IN

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Factors Influencing Machine Rigidity
X-axis on column Constant spindle overhang Guide size & span Ballscrew Size, Precision, Direct coupling with motor Both ends supported by bearings

Bed & Column Mass Y-axis movement on table

MAKI O S33
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Key Technologies

Spindle Technology

Thermal Stability Vibration Control

High Speed Machine

Controller Technology

Processing Speed Shape Accuracy

Mechanical Structure

Rigidity under high speed Thermal Stability

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High Speed Milling vs. EDM
Application
Concurrent technologies HSM
Large molds pre-machining Soft shapes

EDM
Surface quality Deep ribs Angle shapes Polishing

Complementary technologies Milling of graphite electrodes
• Quick and cheap electrode production • Easy undersize optimization

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Pro EDM
• Complex and intricate geometry. Access is not open. • Cost of tool and/or potential damage risk is high. Easier to observe process due to electrode shape and machining process. • EDM finish is specified. Current industry trend favors elimination of polishing and texturing process wherever possible. Conventional EDM requires polishing step before texturing. • EDM is easier to automate than HSM. ormally not the faster material removal process, EDM is more predictable. The entire process from electrode manufacturing through burn can run unattended very effectively utilizing robotic part and electrode loading 24/7. • EDM may be more efficient if there are numerous varieties of geometric characteristics that require extensive programming and application expertise along with a large number of tools. Programming time for electrode is much less than.

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Application Area of Milling & EDM
40
Transaxle

EDM
Ratio L/R 30
Crank Knuckle

Mill
Luggage Inner Head Cover Bumper

L

20
Lower arm Con-Rod Fender garnish Timing Pulley

Grinding

R

10

20

30

40

50

60

Material Hardness (HRC)

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What are EDM problems
EDM is slow machining and
1 Technology dependent on operator and need long time to get experience 2 eed take care especially beginning of machining 3 Poor efficiency 3-1 Long time for setting & programming 3-2 Machine idle during operator absence (ie nights and holidays)

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How CNC EDM can solve these problems?

Conventional EDM Manual setting , Manual adjustment : Stop after 1 condition C C EDM Standardize all machining process : Continue until finishing process : Plural positioning : High accuracy measuring positioning function

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How CNC EDM can solve these problems?

• Standard Model Data
Combination of M/C condition from rough to finish
Select from Electrode : Copper, Graphite, Copper tungsten etc. Work : Steel, Tungsten carbide, Copper ally etc. Suitable discharge area Priority : High Speed , Low wear, Rib, etc 3D orbit mode (Bottom stop complex)

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How CNC EDM can solve these problems?

• Adaptive Control keeps watch during machining
According to machining situation
P pulse A jump : Adjust off time and amperage :Adjust jump cycle and jump amount

High speed jump : For rib M/C

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How CNC EDM can solve these problems?

C C EDM with ATC : Continue to complete 1 cavity C C EDM with Pallet Changer : Final process Outside setting and non stop machining

P P P P 3 5 P 6P 4 2 8 P 7 P 1 P 91 0 P

2 2 3 41

4

3 2

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Makino Sinker EDM Line-Up LineMicro machining Small machining Medium machining

EDAC1

EDFH 1

EDGE2 (EDNC30)

EDGE3 (EDNC40)

EDNC43T

EDNC65

Presetter Large machining
EDGE1P

EDNC85
4

EDNC106

EDNC157

EDNC207

EDNC2015-2H
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Makino Key Technologies for EDM
Machine Structure • Stationary Table • Thermal Stability • Vertical Sliding Tank

Z Y

X

Up Down

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Key Technologies Summary
• • • • • Rigid machine structure Adaptive Control Technology High Speed Rib Machining Technology Super Spark Technology High Quality Surface Finishing (HQSF)

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Successful Implementation
Apart from a good quality machine, success in HSM depends on the following key factors
– Process Knowledge
• Training & Application Support

– Supporting elements
• CAD/CAM Support • Toolings/Work holding/Other Accessories

– Backup Services
• Timely support • Spare parts availability

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Makino’s Technology Center, Bangalore

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Makino Technology Center in Delhi

Showroom Fixture Assembly

Seminar/Training Room

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MAKINO TECHNOLOGY CENTER Key Activities
• Technology Demonstration • State of the art machines • Well trained Engineers • Application Support – DM/PM • Machine Operation Training • Process Training • Turnkey Engineering Services • Manufacturing Process Design • Tool & Fixture Development • Advance Prove-out at Technology Center • Service Support • Maintenance Training • Spares & Service Support
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Thank you

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