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Some key points about mold machining
Release date:
2021-09-02
Under the maximum load that the machine tool can handle, mold machining should utilize the largest possible cutting tools, the highest feed rates, and the fastest feed speeds. With a given tool, however, feed rate and cutting speed are inversely proportional. Normally, the machine tool's load capacity isn’t an issue—instead, the primary considerations when selecting a tool revolve around whether the product’s 2D angles or 3D fillets are too small. Once the right tool is chosen, its length is automatically determined: the tool must be longer than the machining depth. For larger workpieces, it’s also essential to account for the lathe chuck’s limitations.
Under the load capacity of the machine tool, mold machining should utilize large cutting tools, high feed rates, and rapid feeds. With the same tool, however, feed rate and cutting speed are inversely proportional. Normally, the machine tool's load is not a concern—instead, the primary considerations when selecting a tool revolve around whether the product’s 2D angles or 3D curved features are too sharp or delicate. Once the right tool is chosen, its length is automatically determined: the tool must be longer than the machining depth. For larger workpieces, it’s also essential to account for the limitations imposed by the machine’s chuck setup.
The purpose of die finishing is to meet the surface finish requirements for the workpiece while leaving an appropriate allowance. Similarly, when performing precision finishing on the mold, the finishing tool should be used at the largest possible diameter and with the fastest possible speed, as tool changes can be time-consuming and require proper feed adjustments. Under the same feed rate, increasing the lateral feed will result in a faster cutting speed. Moreover, the feed rate applied to curved surfaces directly influences the final surface finish—specifically, the magnitude of the feed correlates with the desired appearance and shape of the curved area. As long as the surface integrity is maintained, ensure an adequate allowance is left by carefully selecting a tool that operates at high speeds with optimized feed rates.
Clamping methods for mold machining:
1. Vise clamping: The clamping height should not be less than 10 mm. When machining workpieces with molds, clearly indicate both the clamping height and the machining height. The machining height should ideally extend about 5 mm above the vise surface to ensure secure clamping without damaging the vise. This type of clamping is considered standard, and the appropriate clamping height also depends on the size of the workpiece—larger workpieces require a higher clamping height.
2. Clamping with Clamps: During mold machining, stack the clamps on the workbench and secure the workpiece to the clamps using screws. This clamping method is particularly effective for workpieces that are difficult to hold due to insufficient height or require significant machining forces—especially when dealing with medium- to large-sized components.
3. Clamping with angle irons: When the workpiece is large, the clamping height is insufficient, and locking screws are not allowed at the bottom, use angle irons for clamping. This clamping method requires a secondary setup—first, machine the four corners while holding the other parts in place, then re-clamp the workpiece to machine the four sides around the previously machined corners. During the second clamping operation, ensure the workpiece remains securely fixed; tighten the angle irons first, then release them afterward. Alternatively, you can clamp and machine two opposite faces first, followed by the remaining two.
4. Tool Clamping: For tools with a diameter greater than 10 mm, the clamping length must be at least 30 mm; for tools with a diameter of 10 mm or less, the clamping length should be no less than 20 mm. Ensure the tool is securely clamped—never strike the tool or attempt to insert it directly into the workpiece.
Mold machining toolpath processing area: The termination surface is defined as the selected face within the chosen range, and the principle is that the tool can descend from the highest point to the lowest point across all accessible areas. The selected surface covers the entire area, with boundaries limited exclusively to the region intended for machining. No single surface extends less than half the diameter of the cutting tool, as other surfaces already have sufficient material allowance and are therefore automatically protected.
Tool selection for mold machining: If the tool cannot perform helical or helical-spiral feeds, or if areas the tool cannot reach are enclosed, it will be reserved for secondary roughing operations.
Before proceeding with mold machining using laser cutting, make sure to remove all areas that haven’t been cut thoroughly—especially those with small angles, including 2D angles, 3D angles, and sealing zones. Failure to do so could result in blade breakage. For secondary roughing operations, a 3D groove-cutting approach is typically used. If possible, opt for planar groove cutting combined with contour tools; otherwise, use flat-bottomed tools instead. Ensure the tool center reaches the selected height without damaging any other surfaces. When cutting grooves that are narrow and cannot be tightened securely, feed the tool diagonally. Additionally, when opening filters—or particularly during roughing on curved surfaces—avoid setting the feed plane too low to prevent tool collisions. Always maintain a safe clearance height to ensure operational safety.
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