116277-apr 2013.pdf

april 2013

Volume 16 / Number 4

DesigN / bu ilD / repair

Essential Cutting

Strategies for

Mold Machining PG 26.

FEATURES

Pairing GD&T with

Industrial CT Scanning PG 30.

Energy Savings in Multi-

Cavity Molds PG 33.

CASE STUDY

Collapsible Cores Compress

Design and Machining

Time PG 17.

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D O U B L E C O LC O U M NM N S U P E R I OR I O R CR C O N TT R OR O L S

Machines shown with options. Information may change without notice.

C O LC U MU M N SS U P EU P E R I O R C O NO N T R O LO L S

PublisherClaude J. Mas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

Metalworking Group PublisherTravis J Egan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

Editorial DirectorChristina M. Fuges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

Senior WriterSherry L. Baranek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

Economics EditorBill Wood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

Contributing Writer, Special Projects Jan Bottiglieri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 847-923-5729 / [email protected]

Art DirectorCarla M. Turner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

Advertising Production ManagerBecky Helton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

MoldMaking Technology magazine (ISSN #1098-3198) is published monthly by Gardner Business Media, Inc., 6915 Valley Avenue, Cincinnati, Ohio 45244. 800-950-8020, 513-527-8800, Fax: 513-527-8801, gardnerweb.com. Canadian Agreement #40012278.Nonqualifed subscription rates per year are $89.00 in the United States, $99.00 in Canada and

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Media, Inc., 6915 Valley Avenue, Cincinnati, Ohio 45244.Entire contents copyright 2013. No portion of this publication may be reproduced in any form

without written permission from the publisher.Views expressed by the bylined contributors should not be construed as a reflection of the opinion

of this publication. Publication of product/service information should not be deemed as a recommen-dation by the publisher. Editorial contributions are accepted from the moldmaking industry. Contact the editor for details. Product/service information should be submitted in accordance with guidelines available from the editor.Change of address: Send old label as well as new address to Circulation, MoldMaking Technology

magazine, Gardner Business Media, Inc., 6915 Valley Avenue, Cincinnati, Ohio 45244.Periodicals postage at Cincinnati, Ohio and at additional mailing offices.

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2 MoldMaking Technology April 2013

6915 Valley Avenue Cincinnati OH 45244-3029P 513-527-8800Fax 513-527-8801 gardnerweb.com moldmakingtechnology.com

Richard G. Kline, CBC | President

Melissa Kline Skavlem | COO

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Kate Hand | Senior Managing Editor

Jeff Norgord | Creative Director

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Dave Necessary | Senior Marketing Manager

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Contents


Features

26 Cutting Tools Essential Cutting Strategies for Mold Machining: Without the right application techniques, even the best tools can fall short of their potential.

30 Inspection/MeasurementPairing GD&T with Industrial CT Scanning: Industrial CT scanning has become an integral part in GD&T and how the internal measurement of complex component parts should be facilitated.

33 Hot RunnersEnergy Savings in Multi-Cavity Molds: Simplifying maintenance and energy savings in the development of hot runner systems.

38 Mold Maintenance/RepairIn the Trenches: Out of the Mouths of Babes: How do you know when youre just fighting fires, performing controlled firefighting or completing true corrective action.

40 Software Circuiting Done Right: Using cooling simulation to circuit your cooling lines properly.

44 Mold ComponentsThink Metric: Its All in the Numbers, Part 2: Feedback from the field on making the metric conversion in your shop.

Departments

6 From the Editor: Where Is Your Top 10 T-shirt?

6 Whats New on MMT Online: Cutting Tools

8 New Business Opportunities: Automation

10 Your Business: Detailed Training Plan

12 Moldmaking Business Index

14 Profile: Association for Advancing Automation (A3)

17 Case Study: Components

20 Case Study: Inspection/Measurement

48 Product Focus

53 MoldMaking Marketplace

54 End Market Report: Aerospace and Packaging

55 Ad Index

56 TIP: Supply Chain Management

ON ThE COvER

Image courtesy of Sandvik Coromant (Fair Lawn, NJ). The CoroMill300 performing helical milling where the cutter is being

helically ramped into the material on a specific angle to a certain

depth. The cutter then machines the entire surface at that level

before repeating. This family of light cutting face and profile

milling cutters has a positive round insert concept designed to

handle a range of operations common to moldmaking.

1. Roll Up Your Sleeves Roll-in and constant engagement techniques by programmed radius move-ments of the cutter create thin chips on exit that maximize productivity.Page 26.

2. Wining Formula Jobs-to-be-done plus GD&T plus industrial CT equals successful internal complex geometry inspection.Page 30.

Energy Boost Keep in mind that en-ergy savings is not limited solely to the system itself (thanks to reduced ther-mal dissipation between system and hot half), but also to reducing scrap during system restart. Page 33.

4. Go With the Flow After determining the best cooling line locations and approximate cooling time, the analyst turns his attention to the coolant fow. Page 40.

5. Metric Moves Being a metric shop will open up opportunities in Europe. The effciency improvements in design will also begin to pay dividends. Page 44.

Apirl 2013 Volume 16 / Number 4

562017

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This MonTh on moldmakingtechnology.com

From the Editor


MMT Zone: Cutting Toolsmoldmakingtechnology.com/zones/cutting-toolsCutting tools are used on machine tools to cut metal, and are one component of the overall mold machining process to consider when looking to improve speeds, feeds, wear and surface finish. Technologies include end mills, drills, inserts, spindles, toolholders, fluids and coatings. There are many styles, substrates and coatings to consider during selection.

Browse Past Cutting Tools Articles by Type: Features, Case Studies and Tips Tips for Successful Hard Milling of Complex Molds:

Emuge shares that when mold and die applications demand hard milling of materials up to 66 HRC, using the right end mills, cutting parameters and machining methods is critical for success.

Taking Advantage of Carbide Material for Your Mold Designs: U.S. Union Tool presents the development of an end mill that can cut 3D features into a carbide material demonstrates how mold manufacturers can reap the benefits of carbide material for their mold designs without a time or cost penalty.

Tooling Up for Mold Machining: Seco Tools reviews the following considerationsmachine tool capability, intended milling techniques, programming, workholding and toolholdingwhich are key for your cutting tool selection process.

Button Cutters Reinvented: Millstar explains how button cutters still offer a competitive edge in many manufacturing processes, despite claims they are being phased out.

Search Cutting Tools Products Cutting Tools Catalog, Tool Alliance Insert Geometries/Customized Toolholders,

Sandvik Coromant End Mill Holder System, Techniks Rotary/Cutting Tools Catalog, Walter USA Extended Length Toolholders, RegoFix

Find a Cutting Tools Supplier via the Following Categories: Coolants Cutting Fluids Cutting Tools End Mills Grinding Wheels High-Speed Electric

Spindles

Browse Cutting Tool Videosmoldmakingtechnology.com/videos/browse/cutting-tools Tips for Successful Hard Milling of Complex Molds Cutting Carbide with an End Mill Improving Milling Accuracy

The past year has shown me that our Top 10 Reasons to

Be a Moldmaker t-shirts have become a little infamous

from shops calling wanting to purchase a bundle for

their team to instructors looking to present them as part

of a reward package honoring their top students to guys

sending me photos showing where the t-shirts have

been how about a family cruise vacation!

I know I enjoy exposing the lighter side of the guys

and gals who work so hard to keep this industry going,

so Im thrilled when I feel it from you too. And so, it is

that time of year again. Time to ask you to submit a Top 10 reason to be a mold-

maker and lets try to top last years list! Im sure you wont disappoint.

Visit: moldmakingtechnology.com/top10/register.cfm to submit your name

and Top 10 reason.

All participants will receive a free exhibit

hall pass to amerimold ($25 value) and the

shirt! Authors of submissions selected for the

Top 10 will receive a free amerimold ALL

ACCESS PASS, which includes: a free exhibit

hall pass ($25 value), a Technical Conference

Pass ($295 value), a ticket to the amerimold

VIP Networking Reception ($50 value),

and your name, title and company name

will be listed in the amerimold 2013 Event

Directory! The author of the #1 Reason to Be

a MoldMaker will receive the amerimold ALL

ACCESS PASS AND a $250 Visa gift card!

This t-shirt has been a tradition of MoldMaking Technology magazine since the

early days of the MoldMaking Expo back in the nineties. Each year these shirts

put the industrys humor to the test and showcase the lighter side of moldmaking.

The final 10 are revealed at our annual trade eventamerimold expo, which is

taking place this year on June 12 & 13 in Rosemont, IL. And we will be distribut-

ing the 2013 custom-printed t-shirts to amerimold attendees who stop by the

MoldMaking Technology booth and complete a simple industry survey.

Now while were discussing reasons, let me give you a few for making sure

you attend amerimold this yearoutside of grabbing your Top 10 tee: our

annual party night; networking opportunities with peers and customers; a

technical conference broken down into Engineer, Build and Maintain blocks;

show floor technology presentations; and, an exhibit hall full of technology

solutions specific to your needs, just to name a few.

So, What Are Your Top 10 Reasons to be a Moldmaker? We want to know

at least your number one reason. The funnier the better, so dont hold back!

Where Is Your Top 10 T-shirt?To get your own, enter your top reason to be a moldmaker.

Christina M. Fuges

Editorial Director

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New Business Opportunities

Moldmaker/Molder Doubles Down

With Technology Investment

By Sherry L. Baranek

Micro Mold Co., Inc. and Plastikos Inc.sister companies

that are based in Erie, PAhave committed to investing 1$

million in capital expenditures this year, which will further

increase moldmaking capacity and cleanroom molding and

further solidify its niche as a medical moldmaker/molder.

The Micro Mold facility is investing in new equipment in

automation and robotics, which Micro Mold General Manager

Ryan Katen points out will enable the company to provide

more 3D EDM work, lights-out operations and overall effi-

ciency, quality and capability expansions. We already have a

very large investment in technology, Katen says. Were con-

sidering the current infusion of capital as doubling down on

our mold shop. At a time when many others are exiting the

domestic toolmaking business

because of its low margins

and ever-growing require-

ments for capital investments,

we see it as a critical compo-

nent to the ultimate success

of our customers end product

in the market. These invest-

ments in automation allow

us to provide high quality,

while remaining price com-

petitive, so that an overseas

option is less and less attrac-

tive to our customers.

Micro Mold currently has

one automation cell and is

now working to build the

second. We added another

machining centera high-

speed Mori Seiki CNCand are tying that into a System 3R

robot to alleviate the bottleneck in the EDM department

and thus further reduce our leadtimes, Katen explains. We

are quoting a lot of multiple tool packages and much of that

work requires these types of machines.

The company recently added a cleanroom to focus on its

medical customer base at its Plastikos facility, and the result-

ing medical business is approaching an all-time high, notes

Micro Molds. Our existing medical customers have grown

and we are in the works of building up some other medical

accounts while looking to acquire some new ones, Katen

emphasizes. We are running out of capacity so hence the

expansion. We want to provide even better serviceand qual-

Phot

o co

urte

sy o

f M

icro

Mol

d Co

. Inc

.

For More inForMation:

Micro Mold Co., Inc. / (814) 838-3404 / micromolderie.com

Plastikos Inc. / (814) 868-1656 / plastikoserie.com

At a time when many

others are exiting the

domestic toolmaking

business because of its

low margins and ever-

growing requirements

for capital investments,

we see it as a critical

component to the

ultimate success of our

customers end product

in the market.

Micro Mold employee Steve Shultz in front of the companys CNC EDM cell.

Plans are underway to add a second cell.

ityfor existing and potential customers.

The addition of an 88-ton Arburg cleanroom molding press

effectively increases the companys molding capacity by 50

percent, Katen notes, and brings the total number of presses

to three. This allows us to meet the rising demand in this

market while giving us the ability to offer Class 10,000 (ISO

7) cleanroom moldinga rare capability amongst contract

molders, he comments.

Katen adds this is a short-term expansion. We are looking

at some other options for a longer term expansion to further

increase our capacities, but for right now this third press

gets us to the next stepping stonegrowing organically and

not trying to do too much, but keeping up with the demand

we are seeing.

Katen is confident that these investments will pay off in the

long-term and result in the companys continued success.

We are just making sure that we are current with equipment

and technology that we need to continue to support the med-

ical industry and its demanding leadtimes.

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Your Business


machine set-ups. What do they need to know before they can

do it? They need to know at least the following (and a lot more):

how to indicate a part straight; proper workholding; how to

identify the axes of a machine, etc.

When a person starts sweeping the floors, they should be

told that they need to know the above items before they will

get an opportunity to advance to machine set-ups. They should

be presented with their options for how the company will help

them learn those items and how they will be measured. When

we develop people before they actually need the skill, they know

they are being trained and they will be able to more easily see

the path ahead of them.

By being able to see the path in front of them through a

robust training plan, employee retention will increase dramati-

cally. Each job description in your company should have a

detailed training plan in place. This will help your employees

see their future in the trade. Our skilled tradesmen and women

are, and will continue to be, who define us as an industry. We

must invest as much effort and planning into how we will

handle them as we do in creating a plastic mold.

By Ryan Pohl

When it comes to the skilled trades, the words training and

retaining are undoubtedly connected. When a company

invests in training for their employees, retention is always

higher. Yet the definition of training can be confusing. In this

industry, people are going to learn no matter what. Whether

they are learning to be a moldmaker, a CNC machinist or a

designerthey are going to learn by simply being part of the

trade. Though there is a lot of learning taking place, often-

times a structured path of training is missing, leaving the

worker confused and sometimes disgruntled wondering if

they have a future.

Learning and training are not the same thing. We can

learn a lot about a topic, but that does not mean we are well

trained. By definition training is structured; it has a start

point and an end point. Training is measurable. Though

learning should never end, we should know when training

is complete. We should know when we are being trained

and when we are not. Most

people can tell the differ-

encethis is why training

is connected with retention.

Employees can tell the dif-

ference between a company

that expects them to learn

as they go and one that has

taken the time to make sure

they are being trained prop-

erly. Employees can recognize whether or not they are being

presented a path of development or a path to nowhere.

This is one of the single biggest ways that companies lose

their employees. They fail to present a clear career path for

their employees. They allow their most valuable asset to be

developed through tribal-knowledge alone. Many of our new-

est workers in the industry are lost because of it. To retain

your next generation of talented workers, you must offer a

clear path of development that is hinged on structured and

measureable training.

This means you must define each job description and map

out the path to get to the next logical job (or jobs) up the lad-

der. The map should include a detailed list of the necessary

competencies needed to progress. For example: if a person

starts in your shop sweeping floors, where would they go after

that? And what would they need to know to get there? It seems

a logical next step from sweeping floors might be to do CNC

contRiButoR

Ryan Pohl is President of Expert Technical Training, LLC.

For more inFormation:

Expert technical training, LLc / (616) 785-5733

[email protected] / expert-technical.com

By being able to see the

path in front of them

through a robust training

plan, employee retention

will increase dramatically.

Finding, training & retaining employees

Part 3 of a Series Detailed training Plan

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Universal Edition

MoldMaking Business Index


Received sub-index for January is 52.9. The

sub-index for Materials Prices spiked up

this month to 73.9. Supplier Delivery Times

are getting longer, and this component

escalated to 53.3 in February. Offshore

orders extended their downward trend last

month, but the pace of decline slowed in

recent weeks. The Exports sub-index is 47.7.

The MoldMaking Business Index is

based on a monthly survey of subscrib-

ers to MoldMaking Technology magazine.

Using the data from this survey, Gardner

Research calculates a diffusion index

based on 50.0. A value above 50.0 for the

index indicates that business activity

expanded when compared with the previ-

ous month, and a value below 50.0 means

that business levels declined.

Total Index for February 2013: 51.3

Rebounding from a three-month downtrend, our survey of

the North American moldmaking industry indicates that

overall activity levels increased in February. The MoldMaking

Business Index for February 2013 is 51.3 (a value greater than

50.0 indicates an increase in business levels for the month).

The latest index value is a 1.5-point increase from the January

value of 49.8, but it is a 7.2-point decrease from the 58.5 regis-

tered in February 2012.

A rise was reported in the crucial New Orders category for

the second straight month, and the Production category also

registered a second consecutive increase. Supply conditions,

as measured by the Supplier Delivery Times and Materials Prices

components, were again the most notable negative factors

in the index this month. Supplier delivery times continue to

get longer, and materials prices have increased for 15 months.

Prices Received remained steady-to-firmer, though the trend

in prices received is not keeping pace with the gains in costs

for materials. Future Expectations were substantially more

optimistic.

The New Orders component posted an encouraging 53.7

in the latest month. The gains in orders so far this year are

notable given all of the uncertainty generated by the poli-

cymakers in Washington in recent weeks. This gain in new

orders meant that the recent slide in Backlogs continued

to decelerate. The Backlog sub-index is 46.3 for February.

The Production sub-index of 54.1 continued to gain momen-

tum from the previous month. The Employment component

is 52.9, which means that payrolls were higher this month.

The prices received in the moldmaking sector gradu-

ally strengthened for the second straight month. The Prices

The growth rate in the U.S. economy has gradually improved through the frst two

months of this year, and this is corroborated by the recent trend in our MoldMak-

ing Business Index. The underlying fundamentals of the U.S. economy continue

to strengthen. The residential construction and real estate sectors are entering

a full-recovery mode, and this is pushing up house prices and household wealth.

The stock market recently hit an all-time high, and this too is generating more

household wealth. The Federal Reserve Board is keeping interest rates extremely

low, thus providing an incentive for companies and investors to take more risk.

Low interest rates combined with rising wealth in the consumer sector and solid

proft levels in the business sector are the ingredients required for a surge in

the employment data. All that is missing is confdence. The recent sequestration

debacle in Washington has dampened enthusiasm in recent weeks, but the nega-

tive effects of this should wear off by the second half of this year. Therefore, we

expect economic activity to chug along at the current rate of growth for another

quarter or two, and then accelerate at the end of this year and through 2014.

Sub-Indices January December Change Direction Rate Trend

New Orders 53.7 54.9 -1.2 Growing Slower 2

Production 54.1 52.1 2 Growing Faster 2

Backlog 46.3 43.8 2.5 Contracting Slower 11

Employment 52.9 51 1.9 Growing Faster 2

Exports 47.7 45.1 2.6 Contracting Slower 9

Supplier Deliveries 53.3 52.1 1.2 Lengthening More 3

Material Prices 73.9 67.4 6.5 Increasing More 15

Prices Received 52.9 51.7 1.2 Increasing More 2

Future Business Expectations 69.2 65.7 3.5 Improving More 15

MoldMaking Business Index 51.3 49.8 1.5 Growing From Contracting 1

55

50

45

40

60

1/13

12/12

11/12

10/12

9/12

8/12

7/12

6/12

5/12

4/12

3/12

2/12

1/12

12/11

2/13

MoldMaking Business Index

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The Association for Advancing

Automation: The Voice of Automation

By Sherry L. Baranek

The Association for Advancing Automation

(A3; Ann Arbor, MI) is a global, not-for-profit

organization for three trade associations

Robotic Industries Association (RIA), AIA

Advancing Vision + Imaging and Motion

Control Association (MCA)that pledges

to be the global advocate for the benefits of

automation in every market space.

According to the A3 Director of

Communications Bob Doyle, the rebranding

of the three associations under the name

A3 is a relatively new strategy. We are dedi-

cated to serving the members of RIA, AIA

and MCA, Doyle states. We sponsor trade

shows, conferences and other networking

events, develop some of the worlds leading

websites on automation technologies, col-

lect industry statistics and generate market

research, develop consensus standards,

provide multiple certification programs and

engage in a wide variety of other education-

al activities. We interact on a regular basis

with people from our more than 650 member organizations

around the world, and are always coming up with new ways

to serve them better.

Of these 650 members, Doyle notes close to 100 of them

are international. Since many automation technologies

are introduced overseas first, we intend to keep our eye on

automation developments all over the world, he notes

While A3 serves as the voice for the need to automate, the

RIA, AIA and MCA will continue to focus on how companies

Attendees gather at Automate 2013a biennial trade show showcasing

the latest in automation technologies.

and organizations specifically can apply robots, vision and

motion control, Doyle notes. Our developing strategy is to

engage stakeholders from around the world and demonstrate

why automation technologies and ideas transform the way

business is done todayand into the future, Doyle notes. To

accomplish this goal, A3s services include the following:

Host business events and networking opportunities;

Media outreach, including placement of opinion

pieces and articles;

Collaborate with other related industries and associations;

Connect with governmental organizations and

nongovernmental organizations (NGOs);

Reach out to international partners to expand its global

network; and

Educate the public on why automation is good.

One of the A3s most important networking events is its bien-

nial trade showAutomate 2013 (automate2013.com), held last

January in Chicago. The A3 also holds a show specifically for the

vision and imaging industries (The Vision Show; visiononline.

The A3 Umbrella

The Robotic Industries Association improves the regional, national and global

competitiveness of the North American manufacturing and service sectors

through promotion and enhancement of robotics and related automation.

The AIA - Advancing Vision + Imaging advances the understanding and use

of vision and imaging technologies to drive global expansion and growth.

The Motion Control Association promotes understanding and use of motion

control technologies and developing business opportunities.

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A3 / (734) 994-6088

[email protected]

a3automate.org

Robotic Industries Association

robotics.org

Advancing Vision + Imaging

visiononline.org

Motion Control Association

motioncontrolonline.org

org; slated next for April 15-17, 2014) on alternating years.

According to Doyle, the companys biggest challenge is to

be the voice of automation and educate potential users about

the benefits of automatingespecially small- to medium-size

companies who may feel automation is out of their realm. We

want to publish white papers and create video testimonials

on our website that share success stories on companies who

have successfully automated and are now reaping the benefits,

Doyle notes. And, while the organization doesnt have any

moldmaker/molder members yet, it is Doyles hope that the

industry reaches out to A3 for assistance in automation solu-

tions to improve the mold manufacturing process.

Additionally, the automation industrymuch like the

moldmaking industryfaces a skilled labor gap. Recently

there was a segment on 60 Minutes that suggested robots are

taking the place of peoples jobs, Doyle states. Our view is

that this is completely wrong and not looking at the bigger

picture. Automation systems create jobs and make companies

more competitive and able to make higher quality products.

This in turn creates jobs that are more technical in nature

and higher paying. In actuality a lot of these companies are

struggling to find people to fill these positions. A lot of our

members cant find people to fill these jobs. The real focus

should be on education at the vocational

education, community college and univer-

sity level to fill these job shortages.

Doyle has a number of short- and long-

term plans for the A3, including expand-

ing the website, extending its global

reach through networking with current

members to develop such contactspar-

ticularly with companies in Europe, Asia,

South America and Mexico, and making

the manufacturing technician (some-

one able to program and run higher tech

equipment) the next skilled trade, like a

plumber or electrician is today.

Phot

os c

our

tesy

of

the

A3.

A robot demo at Automate 2013.

Case Study / Components

moldmakingtechnology.com 17

F&M Tool and Die Co., Inc. (Leominster, MA)a full service

mold manufacturer from prototype to production for a

number of industrieswas asked by one of its customers to

build two multi-cavity molds for a couple of large industrial

parts. The parts were similar but different enough to warrant

two individual molds. The two large, thick-walled parts

had deep undercuts requiring massive side actions and inter-

nal threads that needed to be relieved. Each mold would

weigh approximately 10,000 pounds.

According to F&M Tool and Die President/Owner Michael

Gasbarro, the customers proprietary product line consists

of mostly large, complex parts with slides and unscrewing

mechanisms being the typical approach for the mold con-

structions. The unscrewing mechanisms add to the complex-

ity of both the mold design and build, he emphasizes.

Gasbarro, having built several collapsible core molds in the

past using both RT Series

and Dovetail style (DT)

cores from collapsible core

manufacturer Roehr Tool

(Hudson, MA), approached

his customer with the

thought of replacing the

unscrewing mechanisms in

these two new molds with

DT Cores.

DT Cores are positive,

mechanically actuated col-

lapsible cores that elimi-

nate complex gear and

rack approachesresult-

ing in a simpler mold and

a faster cycle time, notes Roehr Tool Engineering Manager

David Helenius. Additionally, the DT Cores compact design

allows for shorter stack height, tighter cavity spacing, and

also creates opportunities for use in slides or on the station-

ary side of the mold.

F&Ms customer listened to Gasbarro as he explained what

he has found to be the benefits of collapsible cores and the cus-

tomer discovered that they could build one of the tools with the

new to them collapsible core product. The other tool would

have to be built with their traditional methods since the collaps-

ible cores were not suited for that tool without making changes

to their part. Nevertheless the two projects turned out to be a

great side-by-side, simultaneous case study comparing collapsible

cores to traditional unscrewing mechanisms.

Multiple Benefits

It wasnt long before the benefits of Roehrs cores started to

surface, notes Mark Girard, Chief Engineer at F&M Tool. This

customers molds are always a challenge to designcombining

large side actions with unscrewing mechanisms in a multi-

cavity mold, he states. So for the first tool, I started my typi-

cal mold design process, while at the same time sending the

customers second part model to Roehr Tool for the design and

engineering of the Dovetail collapsible cores.

What F&M Tool received

back from Roehr Tool was

much more than the mold

manufacturer expected.

Roehrs engineers designed

the complete DT Core

assembly and provided

conceptual drawings of the

mold base from the parting

line back.

While the project required extra-long DT cores to mold the internal

threads of the large parts, F&M was able to eliminate the need for complex

unscrewing mechanisms resulting in a simpler mold construction and a

reduction in overall mold size.

Speed to MarketCollapsing Cores

Compress Design and

Machining Time


Case Study / Components

Compressed Mold Design Time

What F&M Tool received back from Roehr Tool was much

more than the mold manufacturer expected. Roehrs engi-

neers actually designed the complete DT Core assembly

and provided me with conceptual drawings of the mold base

from the parting line back, Girard elaborates. These draw-

ings showed me the plate stack and thicknesses required

along with the operation and sequence required to function

the cores. After some review of the concepts and an approval

process, Roehr created a complete 3D model of the DT Core

assembly, which I was able to take and drop right into my

3D mold design. Roehrs assistance and upfront engineering

took much of the guesswork out of the second tools mold

design and saved us considerable time.

Roehr Tools Helenius expands on Girards statements.

Over the past couple of years we have added to our engineer-

ing department, and are now able to supply new and repeat

customers with a higher level of engineering and design sup-

port in relation to our products, Helenius comments. We

are also now capable of supplying some customers with com-

plete mold designs or mold retrofit designs in both 2D and

3D formats.

Reduced Machining/Assembly Time

During mold build and assembly, more benefits of using the

DT Cores became evident. Although both molds required

similar side action components, with the unscrewing mold,

multiple components including racks, gears and hydraulic

cylinders had to be manufactured, purchased

and installed, Gasbarro states. With the DT

Core mold, all of this was eliminated. The com-

plexities are integral to the collapsible cores in

a nice compact, modular assembly. The mold

base machining became a matter of a few simple

bores, pockets and tapped holes. Machining

and assembly time between the two molds was

reduced considerably.

Easier Set-up and Start-up

And the benefits did not stop there. When my

customer received both molds, the first thing

they noticed was the physical appearance

comparing the two, Gasbarro says. Without

the visual racks and hydraulics required with

the unscrewing mold, the DT Core mold looked

cleaner, more compact and was much easier

to handle. Installation into the press, set-up and start-up

times were also reduced with the collapsible core mold.

Additionally, Gasbarro notes that both molds started up and

produced excellent looking, functional parts during the initial

sampling, but a problem arose running the unscrewing tool,

when one of the molders hydraulic fittings developed a leak.

Cycle Time Reduction

Gasbarro notes that the molded parts thick wallsa cycle

time limitermeans that the above comparison did not

expose one of the major benefits of collapsible cores, which

is cycle time reduction. But, the other benefits realized right

from the startfrom engineering throughout the mold build

and into productionshould make a good case for anyone

with an undercut or threaded application to consider Roehr

Tool and their collapsible cores.

We will be the first to admit that collapsible cores are not

suited for every application and if a customer sends us a

part for review that would be a better fit with another meth-

od, we will certainly relay this opinion to the customer so that

they can make the best decision for their product, Gasbarro

concludes. However, DT Cores have secured our respect and

a place in our mold building arsenal.

For more inFormAtion:

F&M Tool and Die, Inc. / (978) 537-0290

[email protected] / fmtoolanddie.com

Roehr Tool Corp. / (978) 562-4488

[email protected] / roehrtool.com

Close-up of a custom designed and manufactured DT Core, which provided

F&Ms customer with the required long molding length and deep thread depth.

Phot

os c

our

tesy

of

Ro

ehr

Too

l.


Case Study / Inspection/Measurement

CMM Integral

To Growth Strategy,

Overall Capabilities

CMM operator programming a new job on a CMM.

By Dave Schwab

Yahagi America Molding, Inc. (YAMI, Park City, KY) recently

sought out new metrology technology to capture a greater

share of business from its largest customer. As a result of the

investment, the company expects to nearly triple its revenues

in the next few years because of an increased ability to process

a wider range of partsespecially with tighter tolerance work

with stringent quality control demands.

We were at a pivotal moment in company history, says

Greg Parker, Quality Supervisor with YAMI. Our larg-

est customer wanted to expand the amount of business we

handled for them. However, growth would require technology

upgrades and a mindset with some pretty big changes. Our

strategic partnership with Mitutoyo helped us to increase our

business and develop a stronger relationship with our largest

customer.

YAMI, a Tier 2 automotive supplier making injection

molded parts found throughout Japanese automobiles, turned

to Mitutoyo America Corporation (Aurora, IL) for increased

metrology capabilities found in a state-of-the-art CMM, as well

as their newer contour and surface roughness testing equip-

ment. Specifically with the new CMM from Mitutoyo, YAMI

addressed several points that were important in achieving this

growth goal:

Tighter part tolerances and the ability to measure and

document quality control requirements

Lower production costs

Molding of abrasive materials and how to handle its

detrimental effect on mold wear

Mold maintenance/repair services that can keep up with

demanding production schedules

Original Business Focus in Non-Critical

Tolerance Molding

YAMI was conceived in 2003 to serve the injection molding part

production business for Denso Corporations North American

facilities. YAMI currently produces approximately 4 million parts

monthlydouble the volume from just a few years agofor

various applications. The majority of the parts is found in less

critical tolerance HVAC component parts. Its 27 all electric injec-

tion molding machines range in size from 18 to 280 ton units.

They are fully automated with take out and gate cutting automa-

The appropriate strategy in precision measurement

equipment additions helped YAMI satisfy customer

quality and productivity levels. And the addition of

future in-house mold building/repair/engineering capa-

bilities will help serve their customer base even better.

Phot

os c

ourt

esy

of M

itut

oyo

Amer

ica

Corp

orat

ion

and

Yaha

gi A

mer

ica

Mol

ding

, Inc

.

CUMSA USA, LLC

950 Stephenson Hwy (Suite 106)

MI-48083 - Troy

United States

WEB: www.cumsa.com

MAIL: [email protected]

TEL.: +1 248 850 8385

FAX: +1 248 850 8385

DO YOU WANT TO REDUCE YOUR ?CYCLE TIME

Va

cuu

mje

t S

yste

m

Why we need to vacuum the cavity?

Before injecting the plastic, there is air trapped inside the

cavity. If we can remove this air, the plastic is free to fill the

whole cavity and will not find any counter-pressure slowing

down its flow.

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DO YOU WANT TO OF YOUR PLASTIC PART?IMPROVE THE QUALITY

Application example with Vacuumjet Valve (VV) and Automatic Vacuumjet (VK)

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Application example with Vacuum Control (VM) and 3 Vacuumjet+ (VG) units.

The vacuum is produced through the ejectors and sleeves.

CUMSA has created a series of products that removes this air,

and give many benefits when molding the plastic parts. These

benefits are (among others):

- Lower injection temperature and pressure

- Reduced cycle time

- Increase in production

- Superior visual appearance (less sink marks)

- Dimensional stability (invisible weld lines)

- Uniform color

- High mechanical resistance due to perfect plastic flow

Contact us, and we will find the best solution for your mold!


Case Study / Inspection/Measurement

tion. A total of 150+ different production parts are produced by

YAMI. Annual sales are currently at $8 million and the company

hopes for an aggressive $20 million annual revenue goal within

the next few years.

From Outside Vendors to Inside Mold Building/Repair

Capabilities

With the new material additions came issues on how mold

engineering and repair work would be coordinated. Harder tool

steels and tool coating technologies are often required. Most

molds deliver a million shot life performance. Their heavy wear

glass-filled part molds deliver between a 600,000 to 800,000

shot life performance.

Long-term needs are continually debated. Wed love to own

our own destiny on production scheduling by adding more

internal mold repair/rework capabilities, says Parker. We

envision our facility taking over the responsibilities of ground

floor engineering/design, machining and tryout stages from

customers within the next several years.

The company is currently served by a Japanese mold building

sister company (IMEC Company, Ltd.). Up-front engineering/

build through tryout services are coordinated directly between

the customer and IMEC. They work with Midwestern mold

repair shops for any repair/rebuild needs.

Overall part inventories often need to be maintained at a

two- to three-week inventory because of the repair downtime

required with outside vendors timelines. Bringing the mold

repair work inside will help eliminate larger inventory levels.

Parker says that focusing on better communication between

customer and end supplier would lead to their eventually

bringing much of this mold design/build work to the U.S. He

believes this would have a positive effect on the number of

tryouts that typically take place today (eight to 10 attempts,

on average) versus how a localized response and direct on-site

communication could possibly lead to faster mold approval.

Future Growth in Tighter Tolerance Work

It was quite a challenge to grow toward higher precision

molding work, states Greg Parker, Quality Supervisor for

YAMI. Weve lived in the world of automotive HVAC parts in

which typical tolerances ranged from +/-.1mm to .25mm. Then

Denso started reducing their supplier base of 40-50 compa-

niesand we made the core supplier cut.

While the company could handle the production molding

capabilities, they didnt have a way to check part specifications

to tighter levels and speed of measurement. Before, their only

option was to use local services to check higher tolerance parts.

And at times, they used other limiting hand-held devices and

even a Flexbar Microscope. With larger volume work, they knew

they had to bring that work in house (typically outsourced) for

both precision and productivity.

Two key job additions include an accelerator pedal and base

assembly, as well as a Buss Acceleration Sensor (aka: BAS)

used in airbag assemblies. These parts required a much tighter

tolerance range of +/-.02 to .05mm for those parts. The BAS

part is ultrasonically welded with a metal insert, resulting in a

need for scanning 50 different points across the weld surface

to make sure it meets flatness requirements.

Parker explains that their CMM search needed to measure

quickly, accurately and cost-effectivelywith an obvious and

quick ROI payoff.

New CMM Technology Improves Production Capabilities

Their solution: a Mitutoyo Crysta-Apex CMM. They knew

that CMM technology would not only be able to measure the

tighter tolerance levels, but also handle a higher volume of

part checking.

And while most of their parts could fit in the palm of your

hand, they invested in a CMM that offers a much larger enve-

lope. They expected that future jobs might include larger

part sizes, as well as the ability to check the mold halves

themselves for design/tryout/re-engineering/repair work they

might coordinate internally in the future.

The ability for the Crysta-Apex CMM to handle this type of

tight and unique angled measurement is not an issue due to a

wide range of probe styles/sizes used, as well as an indexable

head probe system that can be easily and quickly configured in

hundreds of different positions.

They operate the Crysta-Apex CMM in multiple modes. The

joystick-driven mode is used for one-off types of checks and

programming. It can also be operated in an unattended mode

when it becomes a daily part checking requirement (build the

fixture, write the program, CNC automatically runs).

Important Features

Measuring range of 27.75" (705mm) X-axis; 27.75" (705mm)

Y-axis; 23.81" (605mm) Z-axis

Measurement resolution to 0.000004" (0.0001mm)

Scanning and touch-trigger probing capabilities

Renishaw Indexable Head Probe System (PH10MQ): 720

indexable positions that take less than 4 seconds to complete

Continuous Scanning Probe

Comprehensive MCOSMOS C3 Software System

Full factory support, training, installation and warranty

A Self-Proclaimed Mitutoyo Shop

YAMIs technology brand loyalty is found beyond CMM appli-

cations. Other Mitutoyo technologies are utilized for their cus-


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tomers specialized metrology needs. One additional example

is found with the BAS part that required specific quality control

checks not capable with existing equipment. For example, a

2mm central radius is checked via a Mitutoyo Contracer CV

3100 profile contour measuring machine. This tight +0/-.2 mm

tolerance check could not be measured by a radius gauge or

other type of measuring device because of the intricate design of

the part, according to Parker. On that same BAS part, an impor-

tant metal insert is checked to a 12 RZ roughness level with

Mitutoyos Surftest SJ-400 portable surface roughness tester.

Critical to that part is the metal inserts roughness level because

the part is ultrasonically welded in downstream operations and

the overall surface must meet a precise surface roughness to

provide a tight fit with its mating part.

Parker appreciates the user-friendliness that both machines

provide, especially in the touch screen capabilities of the

color-graphic LCD and the high-speed printer that prints out

measurement results right at the work space. Both machines

provide a fairly small footprint that works well in their gauge

rooms limited space.

Lessons Learned

The addition of production equipment (e.g., molding machines

and automation) isnt the only solution when trying to grow

your molding companys overall business volume and process-

ing capabilities. In YAMIs case, the appropriate strategy in pre-

cision measurement equipment additions helped them satisfy

customer quality and productivity levels. And the addition of

future in-house mold building/repair/engineering capabilities

will help serve their customer base even better.


Mitutoyo America Corporation / (630) 820-9666

[email protected] / mitutoyo.com

Yahagi America Molding, Inc. / (270) 749-3000

yahagi.webs.com

ContrIbutor

Dave Schwab is a CMM Applications Engineer for Mitutoyo America Corporation.

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Images courtesy of (Left to Right): Siemens PLM Software, Hurco, Aluminum Injection Mold Company and Cimatron

Cutting Tools


By Troy Stashi

Proper cutting action

and chip formation save time,

money and ensure a stable process.

Phot

os a

nd f

igur

es c

ourt

esy

of S

andv

ik C

orom

ant.

Video

Access video

at end of article.

We have all been guilty of reaching for whatever tool

is closest to us to complete a basic milling operation,

thinking we can get by without optimizing the process.

We have also all experienced the resulting poor finish, and that

horrible soundan audible chastisement of our having cut cor-

ners. However, the go-to corrective method of turning down the

feed only masks the real problem, and slows productivity.

When entering into a cut directly, vibration is introduced into

the machining process. This vibration leads to shortened tool

life, poor surface quality and a process that has to be constantly

monitored because tool life cannot be predicted confidently.

Figure 1 shows how the thick chip exists when the cutter leaves

the machining area as it rotates. Also, the tool is under the high-

est loador tool pressurewhen this occurs. This tool pressure

is then very quickly released and causes the milling cutter to

have a slight wobble as the next insert in the cutter body comes

back into the machining process; and, the tool pressure again

increases and loads up the machine spindle bearings again.

All this happens at a very high rate of speed and the result is

a rattling sound until the center line of the cutter is past the

edge of the mold being machined. Once the cutter has moved

to this position, a thin chip on exit occurs naturally. There you

can easily see the difference in thickness of the lines at the fur-

thest point on the right side.

When using the roll-in technique (see Figure 2); however, thin

chips will exit the cutter from the very start of the machin-

ing process, regardless of milling cutter center line position.

This eliminates the tool pressure fluctuation, and loading and

unloading of the machine spindle bearings.

Essential Cutting Strategies

For Mold MachiningWithout the right application techniques, even the best tools can fall short

of their potential. Heres a look at a few key cutting strategiesthick chip,

roll-in technique, radial ramping, helical interpolation, cutter positioning,

conventional vs. climb milling and constant cutter engagement.


The golden rule of milling with carbide

inserts: A thick chip upon entry and a thin

chip upon exit. Always ensure the smallest

chip thickness possible when exiting a cut.

and the thin chip on exit allows this compressive state to be

released on a gradual basis. Again it all happens very quickly,

but carbide inserts are not good at releasing the compression of

a thick chip all at oncethe sudden change in load from com-

pressive to tensile causes carbide chipping on exit. Meanwhile,

for a small engagement typically found in profiling operations,

25 percent of the cutter diameter in cut is optimal for tool life

and productivity.

Its important to keep in mind the potential effects of thick

chips on exit due to cutter position over the mold. Most manu-

facturers center the cutter over the center of the part and thick

Workpiece entry straight inthick chip on exit. Before the

cutter is fully engaged there are thick chips on exit resulting in

edge failure, poor tool life and vibration.

Figure 1

Workpiece entry roll into cut. Rolling into

cut keeps chip thin on exit, reducing vibrations

and giving best tool life.

Figure 2

So in the end, the rolling-in tech-

nique not only eliminates the vibra-

tion problem to increase the tool

life; and therefore, the productivity

of the machining process, it also

reduces machine spindle bearing

wear and yields a more predictable

machining process. Such predict-

ability allows the machine operator

to walk away from the process with

confidence, knowing there will not

be any surprises while his/her back is turned.

Another option for generating thin chips on exit is radial

ramping. If the milling cutter is introduced into the machin-

ing process on a 20 to 30 angle, the same effect takes place as

does with the roll-in technique. This is an option for simplified

machine programming.

Helical interpolation (see Figure 3) is a technique that is used

for machining a pocket or creating a hole in the mold with a

milling cutter. The milling cutter starts out above the mold

and is moved in a circular path as it is lowered into the mold

and begins the machining process. Its a bit easier to get the

thin chip when doing this operation because all it requires is

one additional circular movement

of the milling cutter from above

the mold. The cutter will just start

a little higher above the mold and

move in a counter clockwise cir-

cular path as it progresses towards

and into the surface of the mold

itself. Many people dont perform

this extra step and experience the

same negative effect of vibration,

shortened tool life, etc.

Cutter positioning over the

mold goes a long way in getting

the precision you need. For large

engagement face milling, 70-per-

cent engagement is optimal. It

gives the carbide inserts time to

compress with the tool pressure,

Cutting Tools


Figure 4

process, so re-position the cutter and program to ensure thin

chip on exit at all times. Again, many manufacturers pro-

gram directly over the voids (see Figure 5, top). Not only

does this introduce the vibrations and instability discussed

earlier, it also introduces conventional milling and climb

milling in the same path, magnifying these undesirable

conditions. Instead, they should be using the paths on the

right. Roll-in, keeping constant engagement and thin chip

on exit (see Figure 5, bottom).

For moldmaking there is a lot of profile work done to cre-

ate the intricate features of the molded component. The

same techniques of roll-in and constant engagement by pro-

grammed radius movements of the cutter create the thin chips

on exit that maximize productivity (see Figure 6). There are

also many internal corners in moldmaking, and anyone can

tell you the cutter will normally vibrate when reaching the

corner. The arc of engagement when approaching the internal

corner should be about 50 degrees to remain problem-free.

However, as the milling cutter enters the corner that arc of

engagement increases to 140 degrees due to the material that

exists in front of it, where it hadnt been before. Then, many

manufacturers will make a 90-degree change in direction to

start machining another area of the mold. This causes vibra-

tion because the arc of engagement has increased beyond

90-degrees and the cutter has unloaded.

This means the programmed change in direction has actu-

ally caused the machine to stop moving the cutter altogether,

LeArn MoreVisit our Cutting Tools Zone for more information on end mills,

drills, inserts, spindles, toolholders, fuids and coatings.

Go to moldmakingtechnology.com/zones for a complete list.

Cutter path face milling. Keep cutter constantly engaged.

Rolling into cut when circular interpolating keeps chips thin on exit and

engagement angles lowreducing vibrations and allowing highest productivity.

Figure 3

chips result on exit. Instead, the process should be optimized

to ensure the lowest chip thickness.

Its also important to distinguish between climb milling and

conventional milling. Both are a direct result of the position of

the cutter over the mold. With conventional milling, the cutter

is offset to the right side, again resulting in thick chips on exit.

When using a climb milling pass, the cutter is offset to the left

and chips are thin on exit. This process is referred to as climb

milling because the cutting action is actually pulling the cutter

through the machining process. When conventional milling,

the cutter is being restricted by the compressive forces.

Constant cutter engagement is another path to optimized

productivity. This is to say that the width of cut (width of

material being machined) remains the same throughout the

machining process. Most often in moldmaking, the milling

cutter is moving around the mold creating different fea-

tures. This should be done using programmed radius move-

ments of the milling cutter, and not a series of straight line

moves (see Figure 4).

This is what many manufacturers do, but this is not a good

situation because it loads and unloads the spindle, introduces

the vibration, shortens tool life and greatly reduces overall

productivity. When the roll-in technique is used to enter the

component and then the cutter is moved in a series of radius

movements to turn corners, this keeps chips thin on exit,

keeps the cutter engagement equal (even in the corners) and

provides stability to the process.

Machining over slots or holes will result in an insecure



Sandvik Coromant / (800) 726-3845

sandvik.coromant.com

Contributor

Troy Stashi is an Industry & Application Specialist, Automotive/Milling for Sandvik Coromant.

Videoroll in techniquehttp://short.moldmakingtechnology.com/rollintech

so tool pressure is lost and vibration starts. Then the cutter

takes off in another direction and the tool pressure and load

are increased once again. During the increase in tool pressure

and spindle load, the cutter will continue to vibrate until the

load level is high enough to stabilize the spindle. The correct

process would be to use programmed radii to maintain constant

engagement, spindle and cutter load and to avoid stopping

the machine (see Figure 7). When using a programmed radius,

program using the largest radius possible while maintaining the

constant cutter engagement principle discussed earlier. Ideally,

you would like the programmed radius to be the same as the

cutter diameter, but no lower than 75% of the cutter diameter.

This will ensure favorable cutting conditions.

Summary

Without the right application techniques, even the best tools

can fall short of their potential.However, by keeping the gold-

en rule of milling in mindaiming for a thick chip upon entry

and a thin chip upon exit of moldmaking applicationsthese

processes should ensure the smallest chip thicknesses possible

when exiting a cut. Proper cutting action and chip formation

save time, money and ensure a stable process.

Cutter path when profling external corners. Program radius movements

to drive the cutter around a corner instead of stopping to change machining

direction.

Figure 5

Chip formation and cutter positioning. Machining over slots or holes in

the component will result in an insecure process. Re-positioning the cutter and

machining around these will increase security and maximize performance.

Cutter path internal cornersend milling. Machining into corners is a

vibration hot spot; correct programming of corners will give increased tool life

and allow increased cutting data; consider the change in the arc of engagement

when straight cutting into corners.

Figure 6

Figure 7

Inspection/Measurement


Pairing GD&T with Industrial CT

By Spiro Spiliadis

GD&T analysis using industrial CT scanning for internal geometries

(an aluminum casting).

In the 1960s Theodore Levitt said, People dont want a

quarter-inch drill, they want a quarter-inch hole. Levitts

statement provided us with the understanding that people

who buy products and services do so to accomplish a task

or achieve a goal. These tasks or goals have less to do with

the technology and more to do with the outcomewhat has

come to be known as jobs-to-be-done.

In order to provide you with a solid value proposition for

GD&T through industrial computed tomography (CT)

scanning, I wont present you with what industrial CT is,

how it works or a history lesson on the technology itself. Id

rather present the jobs-to-be-done approach. The notion

is simple, You dont really buy products or services, you hire

them to do a job.

Jobs-to-Be-Done Approach

Turning to industrial CT scanning is an important and viable

step. However, hiring the service providers who can handle

such complex projects is taking that step toward the outcome

of a jobs-to-be-done approach. Industrial CT scanning services

have shown to help moldmakers based on three determining

factors: (1) accuracy, (2) repeatability and (3) savingsboth in

terms of time and costwhen it comes to highly complex part to

print projects, which require numerous GD&T points inspected.

Who really cares about the drill, give me the hole! What moldmak-

ers want most is a smooth transition from part to print request to

a part to print report. This is accomplished by scanning, analyzing

and measuring your part, so that you can make a qualified decision

within a shorter time frame and get to production faster. This allows

you to receive a value-added solution because it increases the value in

actionable data to drive performance improvement, and at the same

time it upgrades standards in quality control.

Moldmakers who handle highly complex geometrical parts on

a regular basis know all too well that anticipating such a highly

complex GD&T project can be time consuming, difficult to mea-

sure and not cost effective at all.

Jobs-to-be-done + GD&T + industrial CT =

successful internal complex geometry inspection

Industrial CT scanning has become

an integral part in GD&T and how the

internal measurement of complex

component parts should be facilitated.

Helps with

Moldmakers Part

to Print Projects

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GD&T through Industrial CT

When it comes to GD&T, measuring for internal features on

component parts has proven to be difficult. Industrial CT

scanning has become an integral part in GD&T and how the

internal measurement of complex component parts should be

facilitated.

Turning to industrial CT for your GD&T projects is a viable

measurement solution for obtaining a complete and accurate

3-D model of the parts internal and external geometries.

Complex parts are scanned in a free-state environment, allow-

ing for both external and internal components to be validated

quickly and accurately without destructive testing.

Once the scan is completed the GD&T program is writ-

ten around the scan data set and referenced to the part print.

From there, the GD&T program is instantaneously applied to

future scans of the same or mirrored part.

Working off a Gaussian least squares model, repeatability

is much higher and measurement programs can be applied to

multiple parts. So once a program is written it can be applied

to subsequent parts as well. Since the software is a virtual

environment, a coordinate system can be created however the

user wants. With its intuitive menu and its approach of apply-

ing sub objects for measurement, the computed tomography

software provides the ability to adjust a sub object, which is then

updated down the chain.

For example, cylindricity call outs are extremely difficult, time

consuming and costly to measure with alternative methods. The

cylindricity function through industrial CTs software with a

CT dataset makes performance calculations as easy as finding a

standard dimension or radii.

Additional value-added features of measuring GD&T through

industrial CT software include:

GD&T with CT datasets can be performed on parts less than

1 millimeter in size

GD&T with CT datasets can be performed on small intricate

parts in 3-D as opposed to 2-D

GD&T with CT datasets can be performed on different

material densities inside a part of an assembly

Industrial CT scanning works by taking several hundred to

several thousands of 2-D x-ray images covering 360 degrees. Once

the scan is completed the 2-D x-ray images are reconstructed in

3-D, giving you the opportunity to see the external and internal

features of the part, inspect for defects, and capture exact geo-

metrical measurements for comparison and metrology purposes.

Summary

GD&T has been an essential tool for establishing design intent,

to make sure that parts meet the requirements of fit, function

and interchangeability. Industrial CT scanning is setting a new

standard in qualifying pre-production parts quickly and accu-

rately while reducing inspection costs. This is achieved by using

the right technology, expert analytical support, and scan data

calibration to ensure accuracy.

The accuracy, efficiency and reduced turnaround time dem-

onstrate that industrial CT scanning will continue its trend of

becoming a required tool for inspection, as industry leaders are

identifying both the value in inspection standards and the cost

savings it offers.

contributor

Spiro Spiliadis is Marketing Manager at Jesse Garant & Associates/JG&A Metrology Center.

For more InFormaTIon:

JG&A Metrology center / (855) 962-5300

[email protected] / jgarantmc.com

LeArn moreVisit our Inspection/Measurement Zone for more information on

coordinate measurement machines and software, probes, vision

systems, balance machines, calibrators and scanners.

Go to moldmakingtechnology.com/zones for a complete list.

An insulin pen showing internal geometries via GD&T analysis using industrial CT scanning.

Stainless

From left to right:

Bryan McIntosh

Operations Manager, Big 3 Precision Products, Inc.

Scott Gibson

Plant Manager, Big 3 Precision Products, Inc.

Charlie Goodwillie

Sales Director - Manager of Special Accounts,

Edro Specialty Steels, Inc.

EDRO Engineering and Specialty Steels, Inc.Call: 1-800-368-EDRO

www.edro.com

RoyAlloy - Boost in Production and Overall ValueBig 3 Precision Products provides complete blow mold tooling systems. We pride ourselves

on quality workmanship, service, on time delivery and building long term relationships.

It allows us to remain a leader in the injection Blow Molding and Injection Stretch Blow

Molding industries. The products, service and relationship we have with EDRO re ects that

of our own mission goals.

Weve chosen EDROs RoyAlloy Stainless Steel for use in all our Die Sets, Machine Parts and

Holder applications as the quality of this product has given us superior performance in the

eld as well as improved ef ciencies during manufacturing.

Weve built the largest cavitation molds in our industry and are challenged every day with

demands for higher cavitation and speed to market. RoyAlloy has helped us meet those

challenges, its corrosion resistance, toughness, ductility and dimensional stability in original

component manufacturing as well as part molding has proven itself in the most demanding

Injection Blow and Injection Stretch Blow Molding applications.

This is exactly the expectations our customers have for our products and why we will

remain with EDROs RoyAlloy.

Scott Gibson Plant Manager, Big 3 Precision Products, Inc.

RoyAlloy Stainless is covered under Patents 6,045,633 and 6,358,334


Hot Runners

Energy Savings In Multi-Cavity Molds

By Massimo Rossi

Constant research into thermo-

plastic materials, and offering

improved performance as a conse-

quence of heightened technical and economic

needs, is leading to an ongoing evolution in mold-

ing. Research involves not only the process but also

the machine and mold, which is in line with the growing

aim to optimize all phases of the production process. The

moldconsidered the fundamental part of the systemis

similarly developing at the same pace. Of particular interest is

detailed research into energy savings, especially regarding the

hot runner.

Energy Analysis

During some hot runner development R&D, finished parts

were analyzed with the aid of specific software to simulate the

systems thermal, fluid dynamic and structural behavior during

the design and engineering stage. System thermal homogene-

ity was also assessed during this analysis phase, estimating

cycle energy consumption and checking any pressure drop and

weight balancing of shots (see Figure 1).

In addition to the use of such instruments, it is essential to

take advantage of those with hands-on experience and exper-

tise, who pay close attention to simplifying system maintenance

and energy-saving issues during any new hot runner product

line development.

Keep in mind that energy savings is not limited solely to the

system itself (thanks to reduced thermal dissipation between

system and hot half), but also to reducing scrap during system

restart.

Hot runners with excellent thermal stability combined

with optimal canalization design are an ideal solution for

many applicationsincluding the medi

116277-apr 2013.pdf

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