The demand for large molds in automobiles is growing rapidly, from interior parts such as dashboards to exterior parts like front bumpers, rear skirts, and so on. But making a large mold is not easy. There are many barriers. The most significant challenge is that large molds are difficult to machine, especially, to meet the tight accuracy and cosmetic requirements.
MEGA Tech is pleased to present the latest cutting tool solution from MOLDINO by Mitsubushi Hitashi Tool, to tackle the problems encountered by many large mold producers.
Large Molds are Difficult to Produce
Size matters in machining. Machining the part of size and weight of a large mold can be a big challenge. You need proper machines and tools from roughing to finishing to guarantee the desired accuracy and quality. There were also roughing challenges, such as deep cavities, overhanging slopes, and other wild geometries.
Some large molds will be machined for days, meaning selecting cutting tools is even more challenging because it can make or break your machining process.
Let’s delve into the details and see how the TR4F type radius mill from MOLDINO by Mitsubushi Hitashi could help large mold makers succeed with the task.
Specially Made For Cutting Large Mold
A new development portfolio from MOLDINO; the indexable milling cutter TR4F (short for: turbo roughing four corner fast-feed) is a high feed cutter with an uneven pitch. The inserts’ unique shape is as much as 10 percent thicker, providing 35 percent more contact surface during milling and helping to boost performance. Wide-shaped pockets on the tool holder ensure better chip removal. This means a tooth feed fz of 2 mm or more is possible during soft roughing. For example, working at a feed rate of 3.5 mm/t and a depth of cut of 2.0×40 mm, a metal removal rate of 740 cm3/min was achieved using the TR4F405000 type (63 mm in diameter).
Besides, the TR4F type is designed to meet the requirements of steel types and various applications, such as face milling, slotting, ramping, vertical, and die-sinking.
Overcome All Major Issues
The TR4F is specially engineered to tackle major issues and challenge encountered by mold makers. This radius mill TR4F type offers a cutting depth of 2 mm × 2 mm feed rate per tooth that help shortening the roughing process time drastically. Moreover, this tool can perform even with the interrupted cutting and high chip resistance condition.
Exclusive high-efficiency cutting, resulting from unique insert and body shapes. TR4F type meets specific challenges posed by high-efficiency cutting. However, there is concern that although high-feed cutting is performed for shaping, resulting severe chip clogging and biting may reduce shaping efficiency. To solve this issue, TR4F adopts new body shape to enhance chip removal. The unique constricted shape helps suppresses chip clogging between tools and wall surfaces, even when cutting long overhangs generating of smooth twist-free chips. The design of large open pocket result in excellent chip removal performance.
As cutting tools are consumable items and they can significantly impact the cost per part and the bottom line of an operation. With this said, tool life is another key factor to consider. As we know, the goal is to reduce machining times with high-feed cutting. But higher feed rates reduce tool life and keep the machine away from delivering its full potential. To extend its tool lifespan, MOLDINO has developed a unique insert shape with cross-sectional and constraint areas is increased from 100% to 110% and 100% to 135% respectively. The larger cross-section secures insert strength and constraint force even in high-load cutting, while the design of unique unequal pitch help reduces chattering during cutting too.
The TR4F is also excellent in wall face processing. Chip ejection path away from work surface prevents scraping due to chip breakage and bending which often occurs during wall face machining, whether cutting up or down.
Another challenge involved in large mold machining included the production of the facets. Some customer’s specifications required virtually mirror-like surfaces and extremely high accuracy. Producing high-gloss surfaces in hard steel always requires high speed and feed rates with the proper tool utilized. The lateral infeed rate, in this case, is critical for the surface quality.
Conclusion
Somebody has ever said that the prime consideration is not how much your tooling costs, but how much it earns. Though the cost of a cutting tool may be not relevant as compared to another but we can’t say that cutting tools can’t have a significant impact on cost and bottom line. So, start your large mold production by selecting the right tools, especially those which specially designed for this special tasks, will take you on the path to success.
Article by: MEGATech & JSR Group << Click here