177075-oct 2013.pdf
TRANSCRIPT
OctOber 2013
VOlume 16 / Number 10
DesigN / bu ilD / repair
Supercharge Rough
Machining with
Advanced Tooling PG 18.
FEATURES
Moving to Metric Yields
More Effcient, Proftable
Moldmaking PG 34.
Selecting the Right Mold
Cooling Option PG 40.
Integrating Electrode
Production PG 44.
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T U R N I N G C E N T E R S M A C H I N I N G C E N T E R S 5 - A X I S D O U B L E C O L U M N H O R I Z O N TA L
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [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.
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©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.
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2 MoldMaking Technology October 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
Richard G. Kline, Jr. | Group Publisher
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Steve Kline, Jr. | Director of Market Intelligence
Ernest C. Brubaker | Treasurer
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Ross Jacobs | Circulation Director
Jason Fisher | Director of Information Services
Kate Hand | Senior Managing Editor
Jeff Norgord | Creative Director
Rhonda Weaver | Creative Department Manager
Dave Necessary | Senior Marketing Manager
Allison Kline Miller | Director of Events
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Great Tips from This Issue5TRICKS OF THE TRADE
Contents
4 MoldMaking Technology October 2013
Features
26 Cutting Tools
Conquering the Complex Task of Tool Optimization
When it comes to coatings, the challenge is the consideration and stream-lining of four influencing factors.
30 Cutting Tools
Cutting Tool Considerations as Mold Complexity Increases
A shop floor look at how to optimize your mold machining operations.
34 Components, Software, Machining, Measurement
Think Metric, Part 3
Insight from technology suppliers on making the metric transition.
40 Mold Design
Mold Cooling Options
Three options for integrating conformal cooling into a core or cavity.
44 EDM
Integrating Electrode Production
CAD/CAM's role in making electrode production completely integrated.
46 Supply Chain Management
Maximizing the Manufacturing Process with an Injection Press
Minimize the overall costs of your customer’s project with the addition of a press.
Departments
6 From the Editor: Opportunity Knocking
6 What’s New on MMT Online: Maintenance and Repair
8 New Business Opportunities: Extend Suite of Services
10 Your Business: Training
12 MoldMaking Business Index
14 Profile: Design Phactory
18 Case Study: Cutting Tools
22 Case Study: Mold Components
50 Product Focus
61 MoldMaking Marketplace
62 End Market Report: Medical & Consumer Products
63 Ad Index
64 TIP: Cutting Tools
On ThE COvEr
Image courtesy of Seco Tools (Troy, MI) and Build-A-Mold (Windsor,
ON). For Build-A-Mold, inserts on its Seco Square 6 high-feed shoulder
mills can be set to true 90-degree cutting angles to create clean
90-degree walls and eliminate secondary operations for the shop’s
plunging operations. See story on page 18.
Images courtesy of (left to right) Sulzer, GF AgieCharmilles and Delcam.
1. Getting on the Same Page. In addition to the right cutting tools, shops should standardize from one machine to the next, so everyone runs the same program, takes the same depths of cut and at the same speeds and feeds.PG. 18.
2. Don’t Forget Your Coat-ing. For PVD coatings, coating companies research op-timized surface solutions in close cooperation with machining companies lead-ing to potential improve-ments in productivity, tool usage and quality.PG. 26.
3. The Finish Line. One of the most common mistakes made in the decision-making process is not leaving enough mate-rial for the fnishing tool. The moldmaker must leave enough material for the insert or end mill to do the actual work. PG. 30.
4. Measuring Up. Increasing acceptance of the metric system will be due in part to CAD/CAM advances. This, along with a better educated work-force, helps encourage the use of any tooling that can bring about productivity gains. PG. 34.
5. Cool Off.There are several options for integrating conformal cooling into a core or cavity: direct metal laser sintering (DMLS), heat/pressure and plate fusion technology.PG. 40.
October 2013 Volume 16 / Number 10
443426
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From the Editor
6 MoldMaking Technology October 2013
Knock, KnockWho’s there? Opportunity! If you are looking for ways to expand
your business or operations, maybe it’s time to open your door
to the opportunities knocking.
Christina M. Fuges
Editorial Director
Perhaps a look at the potential and possibilities
within the global marketplace? Now although
that may be outside of your comfort zone at the
moment, we have some exciting things planned for
2014, the goal of which is to arm you with the infor-
mation you need to consider taking the leap.
We will be kicking off the year in January with
an annual North American moldmaking fore-
cast provided by Steven Kline, Jr., the director of
market intelligence for Gardner Business Media
(MoldMaking Technology’s parent company). This report will examine the
drivers of the manufacturing recovery and spending trends (both general
and end market focused)—all in an effort to deliver better intelligence on the
metalworking and plastics markets that comprise the mold manufacturing
sector. We are very excited about working together on providing such valu-
able content to our audience.
We are also introducing a new print series (alongside a webinar compo-
nent), which will report on the outlook and opportunities for mold manu-
facturers in various regions of the globe. Tentatively, we are looking to begin
with the closest opportunities to home: The Americas—North, Central and
South America.
This data and analysis will be reported by Michael Taylor, Senior Director,
International Affairs and Trade for the Society of the Plastics Industry (SPI).
In this role Michael serves as the primary staff expert on international
trade policy, programs and activities. He has a broad array of experience
in the international trade, governmental and academic arenas, and has a
strong background in U.S. trade law and regulations, as well as in global
compliance issues. Prior to joining SPI, Michael served as Director, Europe
and Multilateral Programs at the U.S. Chamber of Commerce’s Global
Intellectual Property Center, where he developed and executed the Center’s
goals to champion intellectual property rights as vital to creating jobs and
advancing global economic growth.
Through his extensive expertise and experience, we will shed some light on
global market opportunities with a look at trade policy updates, trade flows
and markets, top export markets, top export growth markets, exporting basics,
benefits of exporting, how to develop an exporting strategy, identifying poten-
tial international markets, things to know about the target country, means of
foreign market entry, costs associated with exporting, and more.
And after all that we hope to share your endeavors into the global mold
marketplace.
Follow MMT on: Follow @MMTMag
MMT Zone: Mold Maintenance and Repairmoldmakingtechnology.com/zones/ mold-maintenance-and-repairTo keep a mold running it needs to be properly maintained and repaired. Essential processes include mold tryout, welding, cleaning and retrofitting.
BRoWSe PAST Mold Maintenance and Repair ARTICLeS BY TYPe: FeATUReS, CASe STUDIeS AnD TIPS
• In the Trenches Series A series dedicated to the observations and advice of a tool repair supervisor on how to improve mold mainte-nance and repair operations.
• Shaving with occam’s Razor, Part 1: “How often have I said to you that when you have eliminated the impossible, whatever remains, how-ever improbable, must be the truth?” Occam’s Razor
• Shaving with occam’s Razor, Part 2: Last month we left off in the toolroom asking our-selves “What is different” and the processors had tried every conceivable “tweak” to process out the sink. Now what?
• Taking Mold Repair to the next Level: Improving mold repair efforts—whether you’re on the bench or managing—is not only a worthy goal, but also holds its own reward.
• out of the Mouths of Babes: When it comes to mold repair, how do you know when you’re just fighting fires, performing controlled firefighting or completing true corrective action?
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8 MoldMaking Technology October 2013
New Business Opportunities
Attaining Outside Expertise Yields New Market Niche
By Sherry L. Baranek
When Intertech Plastics Inc. (Denver, CO)—a manufacturer of
custom injection molded plastic products—wanted to extend
its markets beyond industrial plastics and consumer products
into medical, the company decided to look into acquiring a
company that already possessed this expertise. Enter Image
Molding, a Denver-based injection molding and contract man-
ufacturing service provider to the medical devices industry.
Intertech possesses a host of capabilities that include mold
design and engineering support, in-mold decorating, high
cavitation, high volume operations and molding. According to
Noel Ginsburg, CEO of Intertech, the company has wanted to
enter the medical molding market for a number of years. “We
believed the best approach was to acquire a successful molder
who is already in the space,” he explains. “Image met all of our
key criteria—strong customer relationships, consistent profit-
ability, high quality performance, tool building capabilities and
good management.”
Image Molding will join Intertech as the medical division of
Intertech, and will be renamed Intertech Medical by January
2014. Ewan Grantham, President of Image Molding, will con-
tinue to lead Intertech Medical. “The depth of engineering
and management support that Intertech brings will be a great
enhancement here, as will the increased ERP technology and
sales support,” Grantham comments.
According to Keith Hamilton, Intertech’s Vice President
of Sales, the tool design and mold manufacturing in place
at Image has a history of helping customers bring complex,
precision components
into production. A full
machine shop that
includes multiple CNC
and EDM machines
allows the company to
create molded geometry
true to customers’ CAD
files—maintaining a high level of precision through mold
design, mold construction and processing of the molded
components. “My challenge to Ewan at Image Molding was
to have him figure out how to make these super critical parts
with very tight process variability, resulting in a CPK of 1.33
or higher,” notes Perry Croll, Senior Director Anesthesia and
Respiratory of medical device provider Teleflex (Research
Triangle Park, NC). “We were asking him to hold tolerances—
in some cases to ±0.0005 of an inch—in the molded parts. He
has done that on a regular basis.”
In addition to mold fabrication, Tim Nakari, Director of
Marketing for Intertech, notes that this partnership will allow
Intertech to grow in other key areas—mostly cross-selling its
wider range of capabilities. “It will enhance the value-add of
current molding projects at Image,” he comments, “like pro-
viding pad printing and/or packaging and assembly solutions
to existing programs.”
Nakari says this move will also introduce the company’s
medical customers to the new capabilities available to them at
the Intertech Plastics site. “We can now offer larger part size
molding to medical equipment and device manufacturers,” he
explains. “And as we grow, our new customers will be more
strategically aligned with our new host of capabilities—and
in ideal cases—be able to take advantage of our medical part
expertise, high volume part expertise, precision mold design,
and assembly and fulfillment services.”
Ginsburg concurs that Image is a great addition to the
company. “The skills and capabilities that Image brings aug-
ment our capabilities tremendously,” he affirms. “Additionally,
our ability to serve medical device manufacturers is further
enhanced with the addition of even more high-end molding
presses, controlled manufacturing environments, small parts
expertise and medical-specific protocol.”
For More iNForMatioN:
Intertech Plastics Inc. / (303) 371-4270
intertechplastics.com / intertechmedical.com
The skills and capabilities that
Image brings augment our
capabilities tremendously.
An inside look at Image Molding, which has a tool design and mold
manufacturing division in place that will complement Intertech Plastics’
capabilities and allow them to be a full-service provider.
Phot
o co
urte
sy o
f In
tert
ech
Plas
tics
, Inc
.
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Your Business
10 MoldMaking Technology October 2013
By Ryan Pohl
After exploring the broad elements of apprenticeship training
in previous articles, we will take the next couple of articles to
look closer at some of the Related Technical Instruction
(RTI) options that you should consider when building your
apprenticeship program. Remember, as the employer, you
have a great deal of flexibility as to the topics that you put
into your program and how the topics are delivered. Below
is a brief summary of some common topics you may want to
cover, as well as a short justification as to why you may want
to cover them.
Shop Safety: A formal class on advanced safety tips and
rules for working on the shop floor is a critical component to
building a safety conscious workforce.
Shop Math: Many shop owners and managers have argued
that we no longer need shop math in an apprenticeship pro-
gram because “everything is done by computers now”. I agree
that the level of actual math done on the floor has dramatical-
ly reduced; however, I believe shop math is important to keep
in the program because of the problem-solving logic it teaches
us. Perhaps we do not need as much, but I believe it still needs
to be there.
Precision Measurement: Having some type of class that
teaches our apprentices that there is more to precision mea-
surement tooling and layout than just calipers, micrometers
and height gages is criti-
cal. In a good precision
measurement course,
the apprentice will learn
about everything from
proper care of a broad
range of measuring tools
to compounding toler-
ances and more.
Print Reading: Why print reading? Everything is done in
CAD, right? Right! Yet, in my experience of training literally
hundreds of people in this trade, it has become glaringly obvi-
ous that people who have taken a basic print reading course
have better visualization, sketching and overall CAD skills.
CAD systems were developed with traditional prints as their
basis. Sometimes it can be very helpful to understand where
we are if we know where we have been.
Continuous Improvement: Every apprentice should have
at least an overview of the variety of tools, processes and lingo
we use every day to improve our companies and stay competi-
tive. The class or classes should cover everything from Quality
Systems (ISO, etc.) to Lean Manufacturing terms and tools, to
problem-solving tools, such as “5-Why”. These concepts are an
unavoidable reality of modern manufacturing at every level.
We need to be giving apprentices sufficient exposure to how
and why they are used. If we do not, they will stand in the way
of improvement initiatives.
In the next article, we will continue our recommenda-
tions for Related Technical Instruction. There are many more
classes that could prove to be valuable as part of an apprentice-
ship. Again, these are just suggestions. You are free to design
an RTI plan that will fit the needs of your company. However,
it is important to note that the American Mold Builders
Association (AMBA) is working on creating an industry stan-
dard test to validate the knowledge of people completing an
apprenticeship. This also could prove to be a valuable tool
available to us in the near future for setting up your RTI.
cOntRiButOR
Ryan Pohl is President of Expert Tech.
For more inFormation:
Expert tech / (616) 785-5733
[email protected] / expert-technical.com
Shop math is important to
keep in the program because
of the problem-solving logic
it teaches us.
Part 6 oF a SerieS
Finding, training & retaining employees
Related technical instruction Options
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Universal Edition
MoldMaking Business Index
12 MoldMaking Technology October 2013
The Production sub-index of 49.2 indi-
cates that work levels decreased for the
first time this year. With new orders lower
and production levels flat-to-down we
should expect the small decline that was
reported in backlogs—the Backlogs sub-
index slipped to 41.0. The Employment
component was 50.4, which means that
moldmakers’ payrolls were mostly steady,
but the recent rate of expansion slowed.
Prices received were steady-to-down
in August, as the Prices Received sub-index
was 49.6. The upward momentum in
materials prices persisted, but the rate
of increase decelerated, as the Materials
Prices sub-index came in at 59.3. Supplier
Delivery Times reversed their recent trend
of gradual expansion. This component
posted a 47.4 in August. Offshore orders remain weak with the
Exports sub-index coming in at 45.0.
Total MoldMaking Business Index for August 2013: 46.1
Our latest survey of the North American moldmaking industry
indicates that overall activity levels declined in August when
compared with the previous month. The MoldMaking Business
Index for August 2013 is 46.1. The latest index value is a 3.5-
point decrease from July’s 49.6, and it is a 2.0-point decrease
from the 48.1 value posted in August 2012.
This is the first time this year that the Index dipped signifi-
cantly below the breakeven level of 50.0. And the underlying
indicators suggest that business conditions were more negative
than the topline figure indicates because New Orders were down
substantially in August and Production levels also declined.
The good news is that this month’s reading is a contrast to
many major indicators that measure overall U.S. manufactur-
ing levels. The ISM Manufacturing Index in August posted its
highest mark for the year, coming in at a robust 55.7. Demand
for autos remained strong in August, and the recovery in the
residential construction and real estate data is still robust.
Other macro-economic data reported suggest that the U.S.
economic recovery is gaining momentum. According to the
Bureau of Economic Analysis’ second estimate, GDP growth
accelerated to 2.5% in the second quarter, a marked improve-
ment from the advance estimate of 1.7%, and substantially
higher than the 1.1% rate reported for the first quarter. A rise
in exports and nonresidential investment spending combined
with a decline in imports sparked much of this growth.
New Orders was a disconcerting 43.6 in August. Our Index is
not seasonally adjusted, which means that a lot of the decline
in August may be the result of planned shutdowns and vaca-
tions and not because of weakening market demand. Time will
tell, so stay tuned.
Our MBI dipped well below the 50 line, indicating that business conditions in
moldmaking declined signifcantly in August, which may be the result of sea-
sonal factors, so I am not ready to push the panic button just yet. The growth
rate in the overall U.S. GDP data through the frst half of 2013 was 1.8%, but it
is steadily getting stronger. Consumer demand for durable goods remains in a
long-term uptrend, and the moldmaking sector remains in a good position to
experience an increase in activity levels as the overall economy builds momen-
tum over the next few quarters. The labor market likely strengthened, as initial
claims for unemployment insurance continued on their long-term downward
trend, which indicates that job cuts have abated during the past quarter. Once
the employment data surpasses its pre-recession peak—forecast for middle of
next year—wage and salary growth will accelerate and provide increasing impe-
tus for consumer spending.
Sub-Indices July June Change Direction Rate Trend
New Orders 4.36 50.0 -6.4 Decreasing From Flat 1
Production 49.2 53.0 -3.8 Decreasing From Increase 1
Backlog 41.0 43.2 -2.2 Contracting Faster 16
Employment 50.4 53.0 -2.6 Growing Slower 8
Exports 45.0 45.2 -0.2 Decreasing Faster 14
Supplier Deliveries 47.4 53.1 -5.7 Shorter From Longer 1
Material Prices 59.3 64.6 -5.3 Rising Slower 20
Prices Received 49.6 52.3 -2.7 Flat From Rising 1
Future Expectations 74.8 71.8 3.0 Improving More 20
MoldMaking Business Index 46.1 49.6 -3.5 Contracting Faster 2
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
3/134/135/136/13
8/13
7/13
Profle
14 MoldMaking Technology October 2013
The Design Phactory:
Churning Out Creative,
Complex Mold Designs
By Sherry L. Baranek
The Design Phactory, LLC (Zimmerman, MN) was founded by
Russ Salzbrun in 2006 when he decided he wanted to be his
own boss doing something he loved to do that he was already
quite experienced at—intricate mold design—courtesy of an
early job opportunity where he was exposed to every aspect of
building a mold.
“Sometimes, we would literally build a mold off of a napkin
sketch,” Salzbrun comments, “which gave me a great founda-
tion. I always knew that I wanted to eventually design, and
after taking courses and learning ProE, my position at the
company started evolving to include more design work. I’ve
been designing ever
since.” The company
specializes in the fol-
lowing molds: multi-
shot/multi-component,
LSR/LIM silicone,
metal injection, high
cavitation/high pro-
duction, and auto
unscrewing.
His company bills
itself as a design firm
that closely works
with mold shops and
OEMs, designing the
molds that its custom-
ers will then build. The
company’s involve-
ment often starts at
the product design
stage; and other times
it starts after the prod-
uct is already designed
and Design Phactory
does the mold concept
and design. And, all of
the designers Salzbrun hires have a toolmaker’s background
because he believes it is important that the company’s molds
are designed from a toolmaker’s perspective.
Salzbrun has spent the past seven years building a suc-
cessful business focused on “creative, complex mold design”
and problem solving. “Part of my strategy has always been to
invest a lot of time automating the tedious parts of the mold
design process so we can take more time being creative with
the tool design itself,” he elaborates. “I don’t allow us to get
bogged down with the tedious tasks. This really enables us
to produce a high quality design, at a reasonable price. We
always strive to do what’s best for the customer. For example,
when a customer
of ours came to us
wanting us to design
molds for small
parts they make, I
suggested a quick
change modular
system that enabled
them to use small
inserts that were
unique to the style
of parts they were
doing. This enabled
them to make the
inserts ahead of
time and drastically reduce their time and cost of manufac-
turing. Something so simple saved them so much time and
money. That’s our goal—to help our customers save time and
money. We really enjoy taking on a challenge.”
Diligent in Development
The early days were hectic, Salzbrun recalls. He had an estab-
lished relationship with one of his former employers who
fed him work. The company’s reputation grew quickly from
word-of-mouth, and Salzbrun kept picking up clients. “The
company was growing so fast and I couldn’t keep up with all
The Design Phactory employs six full-time designers, who all have a
toolmaker background.
Phot
os c
ourt
esy
of T
he D
esig
n Ph
acto
ry.
Russ Salzbrun, President of The
Design Phactory, has been building his
own business that focuses on creative,
complex mold design.
“One of the biggest advantages
of training a mold builder
who has never designed before
is they don’t come with any
bad habits, so they get trained
in a way that keeps all of the
processes consistent throughout
the company.”
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16 MoldMaking Technology October 2013
of the work, so I hired another designer,
and then another within the first year,”
he says. Currently, The Design Phactory
has six full-time designers and clients
throughout the U.S. Salzbrun would
like to continue to expand his clientele
geographically. “We have found that
not every geographical location is busy
or slow at the same time so it really
helps with work flow to have clients in
the Midwest, South and on both coasts,”
he comments.
Also beneficial is the fact that The
Design Phactory has a diverse customer
base—anyone from small mom and
pop businesses to large OEMs. “Shops
like to use us for overflow, especially
when they get large packages that they
would otherwise have to turn down,
Salzbrun notes. “OEMs that choose to
work with us do so because they want
full control over the design. Usually,
Designers at The Design Phactory work in
SolidWorks or Creo.
once we do a job for a company and they
see our expertise and capabilities—and
the fact that we can design a mold to
their specs—they just keep coming back
because they like what we’ve done.”
Tops in Training
One of the company’s biggest challenges
occurred the very year it was founded—
recruiting new employees. Salzbrun did
not want to turn away work, so he began
wearing too many hats. He learned an
important lesson—to work at a pace he
could sustain for the long-term. “Part of
that process has been delegating, which
has been a new thing for me as I’ve
changed from being a single founder to
growing into a team of eight,” he says.
“Now that we have six full-time designers
the capacity issues are much more
manageable.”
Design Phactory uses SolidWorks and
Creo because those are the programs the
company’s customers use, and Salzbrun
notes The Design Phactory works to
adapt to its customers’ needs. Employees
moldmakingtechnology.com 17
For more inFormation:
The Design Phactory, LLC / (763) 856-9663
[email protected] / designphactory.com
PTC / ptc.com
SolidWorks / solidworks.com
are offered online training through PTC University (ptc.com).
“All of our employees have access to Creo training,” Salzbrun
notes. “That has made it very easy for our employees who
only knew SolidWorks to get up to speed on Creo fairly quick-
ly. I’ve found that having something online is much more
beneficial than sending someone to a class for a week—people
seem to absorb more if they can learn at their own pace. The
Design Phactory is all about staying ahead of the curve; so if
any of our employees want to take a work-related class, we
are all for it and will pay for it.”
engaged in employees
The company invests a substantial amount of money in its
employees’ workspaces. “Besides an ergonomically correct
desk, each employee gets a leap chair, two widescreen moni-
tors and a 3D mouse,” Salzbrun elaborates. “Some people may
think I am crazy for spending $750 on a chair, but if it keeps
my employees comfortable and without a backache, then it’s
money well spent. They could get by with one monitor; but
since a designer’s workflow involves using multiple programs
at any given time, studies have shown that productivity can
increase about 40 to 50 percent when using dual monitors.
We’ve put a lot of thought into what
would be the most comfortable, cre-
ative and productive environment for
our employees.”
As for Salzbrun choosing toolmak-
ers to be designers, he notes that, “It is
much easier to train a mold builder in
software than it is to train a software
user how to design molds. Mold build-
ers make the best designers. One of
the biggest advantages of training a
mold builder who has never designed
before is they don’t come with any bad
habits, so they get trained in a way
that keeps all of the processes consis-
tent throughout the company.”
While this philosophy could be
deemed risky by some because of the
amount of time it takes to train a
designer—especially someone who is
coming off the shop floor to sit behind
a desk—Salzbrun has had nothing but
good fortune. “You do run the risk of
people wanting to go back to the shop,”
he acknowledges. “But, we have been
lucky and have heard comments such
as, ‘I feel like I’m still building molds,
but just on the computer instead of in
the shop.’ It’s a risk that has paid off
for us.”
Stellar in Service
Salzbrun would like the Design Phactory to evolve into a full-
service industrial design firm and provide project manage-
ment services—with the company managing the project from
start to finish. “We will always be a design firm,” Salzbrun
emphasizes. “However, thinking long-term, it seems like the
next logical step for our company. I want to help facilitate the
process of re-shoring manufacturing. Some companies want
more control over production as well as better quality and
leadtimes. I want to help make that easier. Because of all of
our contacts and knowledge that we have in the industry, we
believe that we would be a good single point of contact.”
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18 MoldMaking Technology October 2013
Case Study / Cutting Tools
Rough machining operations for manufacturing a mold can
prove just as critical as the final surface finishing processes.
Approximately 70 percent of the material that needs to be
machined from a typical mold cavity will be removed during
roughing. Therefore, the faster a mold shop can run its rough-
ing cutters, the more it can shorten overall part cycle times, and
increase machine tool throughput—delivering molds faster.
With a simple switch in cutting tools, Build-A-Mold in
Windsor, ON, was able to supercharge the rough machining
performance of its older boring mills and gantry-style mills—
not only doubling, but in some cases tripling, metal removal
rates with the new cutting tools. The company also gained
significant increases in roughing tool life as well.
This 120-person, Tier One supplier shop has been in business
for 34 years focusing mainly on plastic injection molds for auto-
motive exterior (painted) and interior components, in addi-
tion to intake manifolds and other engine components. It also
builds molds for plastic bins and other storage components.
Average mold sizes vary from 5,000 to 80,000 pounds, most
of which are multi-cavity. Many of the larger molds have been
for automotive interior quarter panels and exterior rocker pan-
els. Mold components are made from tool steel, and the shop’s
cutters can range from 0.020" diameter ball nose cutters to
inserted milling cutters 6 inches in diameter. Tool lengths are
as short as 0.125" or as long as 15 inches with the combination
of cutters and holders.
Almost every mold Build-A-Mold machines is high tolerance.
For example, tolerances for the intake manifold molds must
be held to within 0.0001". The shop produces between 150 and
200 molds per year and does all the machining required for its
molds—going from design to finished product.
Fast and Accurate with Costs in Check
The faster the Build-A-Mold can rough cut a mold, the more it
increases machining capacity without having to take on addi-
Seco’s Square 6 high feed shoulder milling cutters immediately
allowed Build-A-Mold to advance feed rates from 145 ipm to over 500 ipm
for high feed rough milling mold pockets.
Supercharging
Rough Machining
Performance
With Advanced
Tooling
Video
Access video
at end of article.
tional machine tools or labor. Plus, the least amount of time
spent on a mold, the more profitability is gained.
As part of the shop’s overall production initiative, Build-A-
Mold’s CNC supervisor Joe Hindi and moldmaker manager
Rob Caixeiro, together with company vice president of tooling
Tony Romanello, turned their attention to the shop’s rough
machining operations on its three-axis, gantry-style and boring
mill machines. The trio then worked closely with applications
experts Ken Adair from Seco Tools and Frank Palombo of WFS
Ltd.—a Seco Tools distributor in Windsor.
Testing Tooling
Hindi and Caixeiro first tested Seco’s Square 6 high feed shoul-
der milling cutters. The 2-inch diameter cutters immediately
allowed feed rates to advance from 145 ipm to over 500 ipm for
high feed rough milling pockets. While these results are signifi-
cant on their own, what makes the situation even more incred-
ible is that it was accomplished on significantly older machines.
Square 6 cutters incorporate trigonal inserts with six cutting
edges for increased productivity and lower cost per edge. The
tool offers three different insert geometries and three differ-
ent pitches, enabling it to provide reliable, high productivity in
face milling, contouring, plunging, slotting and square shoul-
der milling. Square 6 inserts can be set to true 90-degree cut-
ting angles to create clean 90-degree walls and eliminate sec-
Imag
es c
our
tesy
of
Seco
To
ols
and
Bui
ld-A
-Mo
ld.
moldmakingtechnology.com 19
ondary operations. Inserts lock into place via a strong center
screw placed in the same direction as cutting forces, and wiper
flats optimize surface finishes. These inserts can be indexed
2x3 times for a total of six cutting edges.
“No one ever associates high feed milling with older machines,”
Caixeiro points out. “Prior to the Seco tools, we had maxed
out the machines’ capabilities and looked for other avenues to
increase output, mainly through tooling. The old machines pro-
vide the necessary rigidity for high feed cutting and now run at
maximum speeds and feeds with the Square 6 cutters. Yes, we’re
running the machines at their limits, but we aren’t destroying
them. Plus, we get longer tool life as well as the increased output.”
With one of its 2-inch Square 6 cutters, the shop takes
0.040" depths of cut at 900 to 1,200 rpm spindle speeds and
feeding at 250 ipm. These speeds and feeds are the maximum
for that particular older milling machine. What is amazing is
that the shop is confident it could run the Seco cutter at 500
ipm if the machine was capable. It is this reason that Build-A-
Mold is in the process of acquiring newer, faster equipment.
After implementing the Square 6 cutters, Build-A-Mold
brought in Seco’s Double Octomill face milling cutter. And
according to Hindi, like the Square 6 cutters, the Double
Octomills provide longer tool life and increased throughput.
The Octomills are used for backwork—squaring up and/or side
milling—components such as mold cavity blocks on two of the
shop’s horizontal boring mills.
The Double Octomills are 6-inch in diameter and have
10 insert pockets with inserts that provide a total of 16 cut-
ting edges. In current operations, the shop runs the cutter
at 0.125" step downs and full cutter diameter for maximum
metal removal.
These tools work for both roughing and finishing opera-
tions. They were designed in a range of three different
pitches—Normal, Normal+ and Close pitch—allowing shops
to match the right cutter pitch to specific machine power and
speed capabilities, which optimizes productivity for different
machines and materials.
For both its Double Octomill and Square 6 cutters, Build-
A-Mold uses inserts coated with Seco’s advanced Duratomic
technology. The coating process produces a durable coating
by arranging the aluminum and oxygen atoms in a special way
to provide increased toughness and abrasion resistance. The
cumulative result is improved mechanical and thermal proper-
ties together with toughness beyond that of any existing insert
grades.
“Before the Seco cutters, we’d just hog out material as best
we could for our roughing operations,” Caixeiro explains.
“We’d use 2- and 4-inch cutters with standard rounded inserts
as well as button cutters together with multiple machine
passes. Now, when machining molds, such as a big one we do
for producing ATV hoods, we use the Square 6 in a ramping
technique to rough pockets in one pass as opposed to the two
Seco’s Double Octomill face milling cutters provide Build-A-Mold longer
tool life and increased throughput for its backwork—squaring up and/or side
milling—components, such as mold cavity blocks on two of the shop’s horizontal
boring mills. The shop’s Double Octomills are 6 inches in diameter and have
10 insert pockets with inserts that provide a total of 16 cutting edges, and
Build-A-Mold runs the cutters at 0.125” step downs and full cutter diameter for
maximum metal removal.
Build-A-Mold’s moldmaker manager Rob Caixeiro (left), CNC supervisor
Joe Hendi (center) and programmer Jeff Bailey (right) have come to rely on
Seco tooling to boost the shop’s rough machining operations of molds, such as
the big ATV roof mold on the machine behind them.
20 MoldMaking Technology October 2013
Case Study / Cutting Tools
or three passes required with our previous cutters. And with
the Double Octomills, we now take up to 0.200" depths of
cut at full cutter diameter. Our previous cutters handled only
0.100" depths of cut.”
Building Consistency
Build-A-Mold’s boring mills are 50-hp machines and its gantry
mills are 25-hp. Maximum spindle speeds for the machines
used for roughing vary from 1,600 to 3,000 rpm. And accord-
ing to Jeff Bailey, a programmer at Build-A-Mold, rough
machining parameters prior to incorporating the new tooling
were all over the place. Machining times for components var-
ied from one machine and machinist to the next. There was
definitely a lack of consistency, says Bailey.
So, along with adding the Seco tooling, the shop standard-
ized from one machine to the next. Now everyone runs the
same program, takes the same depths of cut and at the same
speeds and feeds. The shop also made its own pallets and
tombstones for standardizing fixturing and pallet systems.
Additionally, shop floor personnel input data into an in-
house developed system for keeping track of machine up and
downtimes, programming time and unattended operation
For Build-A-Mold, inserts on its Seco Square 6 high feed shoulder mills
can be set to true 90-degree cutting angles to create clean 90-degree walls
and eliminate secondary operations for the shop’s plunging operations.
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moldmakingtechnology.com 21
time. For workflow, the shop’s master scheduler uses this sys-
tem as well as a timing system to break down a job by hours
and processes. Then, feeding that information to each depart-
ment, which in turn tracks what has been listed for them to
ensure that process due dates are met.
Build-A-Mold then streamlines part programming with one
programmer developing programs for all the boring mills and
gantry machines. This person knows the shop’s surface finish
requirements and all the machine speed and feed parameters
to be used. Programs are developed in one office, and then get
posted out to the machines.
As far as tooling is concerned, Hindi and Caixeiro are now
focusing on the shop’s drilling operations, and they note that
Seco would most likely help them in that area as well. They
plan to incorporate more inserted drills that will eliminate the
need for resharpening standard twist drills. Seco tooling is also
being considered for mold finishing operations.
Summary
Standardization, a highly skilled team, quality work and quick
deliveries are what set Build-A-Mold apart from its competi-
tion. The incorporation of the Seco tooling is a part of that
For more inFormation:
Seco Tools / (800) 832-8326 / secotools.com/us
WFS Ltd. / (800) 387-2659
[email protected] / wfsltd.com
Build-A-Mold / (519) 737-6984
[email protected] / buildamold.com
drive to standardization, and the shop is making sure the cut-
ters are always used to their maximum capacity. As opposed to
individual machinists each determining what parameters they
think the cutters should be run at. “For us, standardization is
setting the process,” Hindi explains. Build-A-Mold must be on
the right path because it successfully implemented Lean and
5S techniques, and in 2012 business grew by 15 percent.
Video: advanced tools Supercharge rough machining http://short.moldmakingtechnology.com/ buildamold
22 MoldMaking Technology October 2013
Case Study / Mold Components
For one injection molder and toolmaker it was time to examine
a completely new approach to one of the common problems
that arises during the design stage of a plastic injection mold:
undercut release.
Maier S. Coop of Guernica, Spain realized the more complex
injection molded parts become, the more difficult it can be to
remove them from the tool. In many plastic parts, negative or
undercut areas need to be released in order to allow the part to
be ejected. Sometimes it is not possible to do this by means of
a conventional external slide core, so it is necessary to use an
angled device actuated by the movement of the ejector plate
that carries the ejector pins.
Seeking a Nontraditional Solution
The traditional solution to this particular problem has always
been to use lifters or other similarly angled mechanisms that
convert the ejector plate movement into lateral part release,
which allows the undercut to be freed.
However, this has always
required difficult angled
machining operations for the
mold plates and inserts. In
the case presented here, the
molded products in question
are chrome-plated bars on a
car’s front grille—namely, the
Audi Q3 S-Type. The problem
was threefold: (1) the large
angle of the undercuts; (2)
the large number of under-
cuts per bar; and, (3) the high
number of mold cavities.
Once Maier discovered the
undercuts could be released
by using DH series vertical
lifters from Cumsa, the com-
pany contacted the supplier
and learned that a number of
Phot
os c
our
tesy
of
CUM
SA.
Angles Stop
Negative Areas from
Undercutting the
Injection Process
The problems with the Audi Q3 S-Type grille were the large angle of the undercuts,
the large number of undercuts per bar and the high number of mold cavities.
This schematic shows the
complicated mechanical requirements
of traditional-style inclined lifters.
Illustration showing the more
simplifed construction of Cumsa’s
vertical lifter design.
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24 MoldMaking Technology October 2013
Case Study / Mold Components
modifications would be required. Some of them would be rela-
tively easy (such as an increase in the length of the pin), but
others would not be (such as the release of undercut angles of
up to 28 degrees from an ejection stroke of 13 mm).
Cumsa helped by modifying its lifters quickly enough to
allow Maier to develop two different solutions for the same
problem. Maier manufactured two different molds—one with
traditional-style inclined lifters and the other with Cumsa’s
devices.
Time and Cost Savings, Processing Improvements
According to Cumsa, its system provides a range of advantages
during mold construction, which Maier believes includes space
savings, easier machining and simplicity of assembly.
In addition, the system is expected to
also reduce maintenance requirements
for the entire life of the mold. According
to Maier, the machining process has
been simplified and plenty of space
has been freed up in the ejector plates,
which makes the addition of more regu-
lar ejector pins possible, if they should
be required.
With this new design, the required
ejector stroke is reduced, which creates
faster cycle times, hence cost savings,
according to Maier. This can also be
added to the time savings for mold con-
struction, which is quoted at 40 percent
thanks to the ability to machine less and
more easily.
This system also allows two units
to be assembled very closely together,
which in the case of most conventional
lifters is not possible. According to
Cumsa, it is also developing a com-
pletely new range of lifters based on this
concept, which will target large molds
with deeper release movements.
For more InFormaTIon:
CUMSA
(Comercial de Utiles y Moldes, S.A.)
(248) 850-8385 / cumsa.com
Maier S. Coop / maier.es
The new vertical lifter design
provides a range of advantages
during mold construction: space
savings, easier machining and
simplicity of assembly.
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Cutting Tools
26 MoldMaking Technology October 2013
Functional coating properties—such as layer hardness, phase stability and tribological properties—
can be adjusted by a different distribution of the elements within the layer.
By Annette Norin, M.A.
Machining is a metalcutting process that has to
fulfill increasingly high demands with regard to
productivity and processing speed. The friction
arising during the process and the wear on components and
tools are major loss factors. According to the German Society
for Tribology, a loss of about five percent of gross social
product arises annually in industrialized countries through
the effects of friction and wear alone.
Tool coatings (see Figure 1) counter these mechanisms and
so are essential in machining. Providers of surface technolo-
gies have been developing tailor-made coating solutions for
many years to make tools more resistant, more productive and
longer lasting. The unique challenge is the consideration and
streamlining of four influencing factors:
Standard coatings can help,
but to achieve really impressive
results all the factors must be
coordinated with one another—
from the base material of
the tool to the post treatment
of the coating.
Conquering the Complex Task of
Tool Optimization
1. Pre- and post-treatment of the tool surface
2. Coating material
3. Layer architecture
4. System technology with which the coating will be applied
Origin of Wear
During the machining process, some wear mechanisms take
place in the area the tools contact the material. For example,
adhesion between chips and the cutting surface; abrasion
through hard materials within the material; and, tribochemi-
cal reactions (chemical material behavior due to mechanical
action and high temperatures). These tribological stresses
largely characterize the efficiency of tools because they reduce
the cutting forces and shorten service life.Im
ages
cou
rtes
y of
Sul
zer.
Monolayer Graduated Layer Multilayer Microalloyed Layer Nano-Composite Layer
Figure 1
In machining, everything depends on the optimal interplay of all the
parameters of the tool, the coating and the material.
moldmakingtechnology.com 27
Coated milling tools have considerably increased service lives,
even in the high speed machining of hard steels.
A surface coating may reduce the impact of the tribologi-
cal stresses, while the base material of the tool takes over the
supporting function and absorbs the mechanical stresses. In
addition to increased productivity, improvement in the tribo-
logical system also leads to savings in material and energy.
Impact of Coatings on Machining Cost Reduction
An important cost factor in the production cycle is the ser-
vice life of the tools. Among other things, this is understood
as the period during which a machine can work without
interruption before it requires maintenance. The longer the
service life, the lower the costs that arise due to production
interruptions and the lower maintenance work will be.
The use of coatings increases the service lives of the
tools—even at high process temperatures—and thereby, con-
siderably reduces the costs. In addition, fewer lubricants are
needed. This not only reduces the material costs, but also
helps protect the environment.
Impact of Pre- and Post-Treatments on Productivity
In modern machining processes the cutting tool is subjected
to high pressures (more than 2 GPa), high temperatures and
thermal cycling stresses. The pre- and post-treatment—as well
as the coating—must be adapted to the application.
There are various pretreatment methods available that
prepare the tools for a subsequent coating process, signifi-
cantly improving the coating adhesion at the same time.
Together with the coating, a preparation of the cutting edge
of the tool leads to increased cutting speeds, feed rates and
longer service lives.
The post-treatment (edge preparation, surface treatment and
structuring) also plays a decisive role. In particular, in avoiding
initial wear that can occur through cutting edge buildup (adhe-
sion of material from the workpiece to the cutting tool).
Coating Considerations and Options
The requirements that are placed on coatings can be very dif-
ferent. As high temperatures arise at the cutting edge during
machining, high resistance to thermal wear becomes extremely
important. The following properties are expected from modern
coatings: excellent high-temperature properties, resistance to oxi-
dation, high hardness (even at high working temperatures) and
microductility (plasticity) through a nano-structured layer design.
In the case of high-performance tools, optimal adhesion
of the coating and well adapted residual stress are decisive
factors. Above all, this applies to the interaction between the
base material and the applied coating. The coating material
should have the least possible affinity to the material being
worked on. In this way—with suitable cutting geometry and
by smoothing or polishing of the coating—the adhesion ten-
dency can be significantly reduced.
Aluminum-based coatings, such as AlTiN (titanium
aluminum nitride), are often used in the machining industry.
In these aluminum-based coatings, a thin but dense aluminum
oxide layer forms as a result of the high temperatures during
machining. This layer then continually and independently
View into a PVD coating chamber.
Cutting Tools
28 MoldMaking Technology October 2013
renews itself, and protects the coating and the base material
below it from oxidative decay.
The required hardness and resistance to oxidation can
be adjusted through a variation of the aluminum content and
the layer morphology. For example, the resistance to oxidation
can be improved through an increased aluminum content,
nano-structuring or microalloying (i.e., alloying with low-
percentage element proportions).
In addition to the chemical composition of the material, the
layer architecture can also considerably alter the properties of
a coating. Different tool properties arise depending on the dis-
tribution of the elements in the microstructure of a layer.
Today, several individual layers with different chemical
compositions can be combined to achieve customized proper-
ties. This trend will increase even more in the future—par-
ticularly through new system and process technologies, such
as the HI3 (High Ionization Triple) technology that is an arc
and sputtering hybrid technology, combining three high ion-
ization processes.
Titanium-silicon-based (TiSi) coatings provide outstanding
results as all-rounders. These coatings can be used for very
hard steels (up to 65 HRC Rockwell core hardness) with a vari-
able proportion of carbide as well as for medium-hard steels Coated cutting tool.
Order today. Contact Single Source
Technologies at 877-228-2884 or visit
singlesourcetech.com.
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© 2013 Single Source Technologies.
moldmakingtechnology.com 29
cOntributOr
Annette Norin, M.A. is Public Relations Manager for
Sulzer Metaplas GmbH. She graduated with a mas-
ter’s degree in Communication Science and Material
Science from RWTH Aachen University, Germany and
has been working three years for Sulzer Metaplas in
Germany (a Sulzer Metco Company).
For more inFormation:
Sulzer / [email protected] / sulzer.com
(919) 485-6002 / [email protected]
(40 HRC Rockwell core hardness). The layer design is similarly
adapted in order to meet the diverse range of application
areas. As a result, the surfaces are equipped for the machin-
ing of everything from high- and low-alloy steels to hardened
materials and titanium. In short- and long-term tests, TiSi-
based coated copy mills showed service lives that were almost
doubled due to reduced cutting edge wear and enhanced sur-
face quality. Further tests carried out in
the fine-finish machining operation (on
flat workpieces with a Rockwell-hardness
of 44 HRC) made it clear that a service
life that is almost three times as long and
a tenfold reduction in roughness can be
achieved with coated tools.
The subsequent polishing of the sur-
face could be minimized. Such coating
families have potential in applications in
which high cutting speeds, high tempera-
tures at the cutting edge and high metal
removal rates are required.
For additional PVD coatings (and in
particular, for micro alloyed coatings),
coating companies also carry out research
on optimized surface solutions in close
cooperation with machining companies.
As a result, potential improvements in
productivity, tool usage, quality, and
the interplay between material, coating
and application can be realized and uti-
lized. Through expert coating partners,
customers can increase the efficiency of
machining tools throughout their com-
plete life cycle.
Learn more
Visit 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.
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Cutting Tools
30 MoldMaking Technology October 2013
Cutting Tool Considerations
as Mold Complexity Increases
By Tom Piper
The choices moldmakers make when it comes to toolhold-
ing and machining impact each job. Here is a look at some
of the factors to consider when investing in cutting tools.
Toolholders
Modern Weldon flat end mill holders are better than they have
ever been; however, they still push the rotational centerline of
the tool off center when tightened. This eccentric condition has
a negative effect on tool life and surface finish (see Figure 1).
Modern collet holders are also much improved, but still flex
if tool pressure exceeds their stiffness. However, they are a
very economical choice for finishing. Shrink fit holders are an
appropriate choice if the tool has a carbide shank. Hydraulic
toolholders offer an ideal combination of strength, accuracy
and convenience.
Tool Length
Tools need to be as short as possible in any machining operation
because excess length reduces stability, which results in poor fin-
ishes and reduced tool life. It also inhibits aggressive feed rates.
Modern modular extension systems add rigidity and stability
to cutting tools while maintaining concentric rotation.
Insertable Carbide Insert Holder Material
When extension lengths are reasonable, traditional low alloy
tool steel insert holders are cost effective and efficient. When the
extension increases, different materials need to be considered.
Switching to H13 is an option when trying to stay with steel
for the insert holder. A carbide core, which can be inserted into
the tool steel holder, is a good first step because the carbide adds
stiffness and vibration dampening while keeping the cost low.
The next step up on the stiffness ladder would be to use a car-
bide shank, but then to braze a steel tip onto the end of the car-
bide shank. The final step is to have a holder made of a machin-
able carbide grade. The cost is high, but the material is rugged,
accurate and durable.
A look from the shop foor at some of the factors to consider during
your cutting tool selection decision-making process to optimize your
mold machining operations.
FIgure 1
Correct orientation of ball nose finisher and Weldon screws.
Carbide and Coatings
Currently there are cutting tool manufacturers making inserts
and holders that use a system1 where the screw goes through
the insert. Many operators are not aware of the true function
to the screw and don’t change it often enough (see Figure 2).
The screw preloads the insert into the bottom of the slot
as well as centering the insert radially. The high pressure
Regular and proper insert replacement and installation is essential.
Phot
o co
urte
sy o
f Lo
vejo
y To
ol C
o. I
nc.
FIgure 2
Cutting Tools
32 MoldMaking Technology October 2013
and resulting wear on the barrel of the screw
requires it to be lubricated every time an insert
is changed—as well as replaced every 10 inserts
when finishing. Also when finishing, the hold-
ers need to be replaced every 10 boxes of inserts.
Toolholders and inserts do not need to be dis-
carded at this point, but should only be used for
noncritical, semi-finishing.
The diameter, length of cut and extension are
all considered when deciding whether to use
an insert or an end mill. A point of diminishing
financial return is reached when the cost of an
end mill is lower than the cost of the insertable
tool. This varies, but is usually below ½-inch
diameter. Carbide grades and grinds are continu-
ally being improved, but the increases in tool life
and chip formation have been smaller in the past several years.
Most of the significant improvements have been in coatings
in terms of taking the residual stress out of the aluminum
oxide coatings, which have the properties moldmakers seek.
Aluminum oxide-based coatings are harder and resist heat
damage better than other coatings.
Roughing
The traditional concept of roughing at low spindle speeds,
deeper depths of cut and higher chip loads has changed sig-
nificantly in recent years. Lighter, faster, shallower depths of
cuts are now the norm when performing one of the earlier cuts
on a mold or die. The main reasons for the changes in how
roughing operations are performed are speed and safety. Speed
because more material is removed in a shorter time and safety
because if an insert breaks, the damage to the tool and part are
not catastrophic, and easily fixed or replaced.
Z axis or plunge milling is also gaining acceptance and
favored when deeper cuts with straight walls have to be made.
Plunge milling puts most of the cutting force axially up into
the spindle, which increases stability rather than radial side
pressure, which tends to force the toolholder out of the spindle
socket. The design of the tools and inserts allows larger diam-
eter cutters to increase metal removal, but still transmit most of
the cutting forces back up into the spindle.
Finishing
One of the most common mistakes made in the decision-
making process is not leaving enough material for the finish-
ing tool. We still have to create enough chip during the cut to
absorb the heat that we need—and have to create with spindle
speed—to soften the material at the cutting edge. The mold-
maker must leave enough material for the insert or end mill to
do the actual work. A good rule of thumb is width of cut should
be equal to or greater than the depth of cut for ball nose cutters
and feed per tooth should be equal to the depth of cut. There
is a great deal of chip thinning occurring during a ball nose
or bull nose cutting operation, and the feed rate needs to be
higher to avoid rubbing and to create enough mass in the chip
to absorb the heat created during the cut (see Figure 3).
Coolant
A final thought is the use of coolant. Traditional coolant may
not be the most appropriate choice when it comes to machin-
ing cores and cavities. Some prefer air to move and keep the
chips away from the cutting edge. Metered coolant delivery
systems are a good choice because you still get the advantages
of lubrication and cooling without the danger of thermal
shocking—and if a vegetable-based oil is used there are no
health concerns.
Summary
Simple, relatively flat molds are easily machined using shorter,
robust tooling with conventional concepts. Complex or deep
molds require different tools and cutting concepts. Choosing
the correct ones saves time and money. Faster, lighter cuts are
easier on the operator and on the machine. Roughing can now
be done on an unattended basis the same way that finishing is
currently done. Shop operators must be constantly on the look-
out for innovative ideas to stay current on tools, coatings and
concepts.
RefeRences
1 Walter Kieninger Company.
FoR moRe inFoRmation:
Lovejoy Tool Co. Inc. / (800) 843-8376 / lovejoytool.com
COnTrIbuTOr
Tom Piper is a territory manager for Lovejoy Tool Co. Inc.
FiguRe 3
Width of cut should be equal to or greater than depth of cut.
Sli
din
g s
olu
tio
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Components, Software, Machining, Measurement
34 MoldMaking Technology October 2013
Screen shot illustrating how some software can
change a parameter in a part from ‘mm’ to ‘in’ by
simply entering ‘in’ after the value in the input feld.
By David Frost
Pho
to c
our
tesy
of
Siem
ens.
You are a manager at a modern mold manufacturing
company and after watching a news special on the
extent of the European tooling market, your owner
has an epiphany. He approaches you to say that the company
is going all metric, and you have two weeks to make the tran-
sition and get up to speed. Questions immediately come to
mind. You know you make a great mold in inch, but can you
still make a great mold in metric? Where can I go for help?
For some advice, we sought the input of technology suppli-
ers within the areas of mold design and manufacturing soft-
ware, CNC machining, cutting tools, mold components and
measurement equipment. We received responses from several.
These companies and many others are willing and able to
lend their knowledge and expertise to make the transition to
metric smoother, so be sure to discuss this trend with your
technology suppliers.
1. Design
When it comes to design software
parameters, Siemens PLM Software
Marketing Director Aaron Frankel
shares some insight about working with
metric, “At its core, Siemens NX is a
system that automates the mold design
process and captures the way the end
user wants to work to automate their
job. At the set up of each job or project,
inches or metric is a selectable option.
The user can set and define any param-
eters at the start, and add additional
parameters as they go.”
Insight from several technology suppliers—in design software, mold
components, programming, machines, cutting tools and measurement
equipment—who have been following the metric trend may help to
make the transition a smooth one.
Think Metric ParT 3
Of note is that a design file can be exported in different
ways. “The raw data may or may not specify units depending
on the file type; however, if you import a file with set units,
they will be specified based on the unit of the file that it’s
being imported to,” explains Frankel.
Pro/E user Gary Saperstein offers the following: “It doesn't
care if it is metric or imperial. Designing in metric is much
easier than imperial mainly because no fractions are used.
When I was at AMP, the mold design units—if not stated by
the buyer—were in the unit of the product design. Then there
is the discussion of hard metric versus soft metric (where the
size of the part is a nominal inch size converted to metric
numbers). And finally, the discussion of dual dimensioning
with what unit is primary and what unit is secondary. Pro/E
handles all scenarios.”
moldmakingtechnology.com 35
EDRO Engineering uses
custom gauges for calibration
of inspection instruments to
standard metric mold base
diameters.
Chris Outlaw, an Engineering Manager at Cavaform uses
Solidworks as his design software, and says, “Setting up
SolidWorks part files for metric is rather simple. It has a tool-
bar in the lower right side of the application that allows you
to toggle to the desired unit system at any point during the
design. The drawing files are very easy as well; however, it is
better practice to set the drawing up in the desired unit system
from the start of the project.”
2. Components
As designers begin to make the change to metric they will need
a source for the mold base—standard or custom—as well as
other mold components. Standard metric mold base sizes and
mold components are available from many companies.
For custom bases EDRO shared how they handle the metric
issue. Over the past decade, the company has seen large overseas
corporations extending their operations and mold manufactur-
ing to the U.S. through acquisitions and expansion—creating
a global mold market. Many of these companies require their
molds to be designed and built in metric, especially if the tool
will run in another country to allow for local maintenance.
In response to this trend, the company has aligned its oper-
ations to produce imperial and metric mold bases side-by-
side. Currently metric jobs make up approximately 30 percent
of their builds.
As Guy Recendez, EDRO’s Operations Manager describes,
“A metric job is handled as a metric job start to finish—no
conversion to decimal, which could create errors. We have
the set ups, programming, tooling, procedures and inspection
equipment in metric.”
In addition to complete mold base manufacturing, they
also produce a stainless holder steel grade commonly used
in mold base applications. Over the years, the company has
added certain metric plate thicknesses to its stock program to
adapt to the increase in metric mold plate demands.
A unique steel production approach allows for flexible and
quick replenishment of both imperial and metric gauges,
as well as the ability to quickly produce any custom plate
sizes. This allows for less material removal from raw to finish
machine sizes, as opposed to achieving a metric plate thickness
from the next available imperial gauge size up.
HASCO has been supplying metric mold bases and com-
ponents for the plastics industry for decades. Louis Hébert,
Managing Director from HASCO Canada explains, “Our mold
base sizes are based on the most common injection machine
platen sizes. Typically, there would be a minimum of 2-mm
clearance per side between the tie bar and the plate edge. All
plates can be purchased separately and are fully interchange-
able. This gives more flexibility for design. Also, the plates are
built with high precision, so reference location for additional
CNC machining is easily done.”
Hébert also points out that he has more options in metric
because increments are tighter. For example, in some size
ranges ejector pins come in 0.10 mm or 0.0039" versus 1/64
increments or 0.0156". Now pins can come in 0.010" incre-
ments, but this shows how the metric system allows for more
design options without having to use special custom sizes.
Phot
o co
urte
sy o
f Ed
ro E
ngin
eeri
ng a
nd S
peci
alty
Ste
els,
Inc
.
Learn MoreVisit our Mold Components Zone for more information on mold
bases, pins, ejectors, lifters, bushings, guides and alignment
devices, and more.
Go to moldmakingtechnology.com/zones for a complete list.
3. Programming
CNC programing is a key part of the process to move from
design to machining. Perhaps the earlier statement, “with
programing software you can easily switch from inch to metric
and back” was an oversimplification. To get a real understand-
ing of what is involved, here is input from two CAM software
suppliers.
Peter Dickin, Marketing Manager over at Delcam, spoke to
one of the company’s engineers and was assured that switching
from imperial to metric is a simple change of setting; however,
the choice must be made at the start of the project when all
the default values appropriate to the chosen system are set. “It
is much more complicated to change mid-project, but this is
unlikely to be necessary,” explains Dickin.
One trick Dickin shares is the ability to use sizes from the
other system during a project. “For example, a U.S. user might
be doing a project in inches, but wanted to use an imported
cutter that was supplied only in metric sizes. He can simply add
‘mm’ after the dimension and it will be converted automatically
to the equivalent inch dimension.”
Over at Mastercam, Doug Nemeth, Corporate Sales
Manager notes, “It can be configured to start up in either met-
Components, Software, Machining, Measurement
36 MoldMaking Technology October 2013
ric or imperial units, and users can easily switch between the
two in a given session.”
Nemeth continues to explain that in a metric configu-
ration, not only are the units used in metric, but all tool
libraries and default settings are also in metric. He says that
there is no need for the user to do any conversions to get the
metric values they need. Understanding that some users may
need to use metric settings in an imperial environment, they
do allow this.
Also according to Nemeth, “If a user is in an imperial con-
figuration, but needs to enter a value such as a tool stepover
in metric, they only need to type in the metric value followed
by ‘mm’ and the system will automatically convert the metric
value to inches.”
4. CNC Machining
As most CNC machines are built to metric standards in Europe
and Japan, it is not surprising that there is a metric option
available. Actually, inch is the option; metric is the standard
for these machines.
Gisbert Ledvon, Director of Business Development at GF
AgieCharmilles agrees that the metric switch is easy with
many of today’s machine tools. “For our advanced EDM and
high-speed milling machines, the transition from metric to
inches and vice versa is basically done with the flip of an
electronic switch; and because the capability is essentially
a parameter within the machine’s control, shops can make
the measurement switch at any time to easily accom-
modate programs with either metric or inch dimensions.
Additionally, our machine controls allow shops to switch
languages as well.”
For high-precision mold machining, Ledvon recommends
working in metric and refraining from converting dimen-
sions to inch because in these applications, shops using metric
machine movements eliminate the risk of possibly losing a
very small amount of accuracy. For example, dividing all of the
numbers by 25.4 to switch from metric to inches can result
in rounding that reduces precision by several microns over a
meter of machine travel.
In the case of wire for wire EDMs, machining inaccura-
cies can result when shops convert wire, which is produced
in metric diameters, to inches. To illustrate, wire that is 0.25
mm is actually equivalent to 0.0098". Yet, most shops will typi-
cally reference it as 0.010", which is actually 0.254 mm in their
machining operations.
Over at Okuma, Rick Kimmis, an inside sales specialist, says
“On our machine all the tool lengths and parameter settings
will change as a result of changing this parameter from inch to
metric or visa-versa.”
As for the number of customers running their machines in
metric—in the U.S it is around 35 percent. Typically, Asian,
South American and/or European implant companies will run
For high-precision mold machining, it is recommended to work in metric
and refrain from converting dimensions to inch. The reason is that in these
applications, shops using metric machine movements eliminate the risk of
possibly losing a very small amount of accuracy.
Phot
o co
urte
sy o
f G
F A
gieC
harm
illes
.
in metric mode. Notably, if the part drawings are in metric, the
programs will also be produced in metric.
Kimmis continues, saying that in some cases metric is
easier to use for programming, dimensional drawing and part
measuring. “In inch mode we typically program to 0.001" or
0.0001". However, in metric mode programs are carried out to
3-decimal places of 0.001 mm, which is around ½ of a tenth in
inch (0.0001") mode. Metric mode allows the machine opera-
tor a finer increment of machine/tool adjustment for parts
that can be closer to tolerance and is one less decimal place to
consider.”
As for high-speed machining, moldmaking and processing,
Kimmis prefers to run in metric and notes that most controls
run in metric behind the scenes.
To summarize: 0.001 mm = 1 micron and 0.0001" = 2.54
microns.
5. Cutting Tools
No one can argue that most cutting tool options are avail-
able in both inch and metric. Steve McBride, OSG High Tech
Group Manager believes it is important for U.S. moldmak-
ers to start working exclusively in metric because there is a
market for U.S. molds in Europe if we are fluent in metric.
moldmakingtechnology.com 37
A metric cutter combined with
high-speed machine features
within a CAM system enhances
cutter performance by creating
better cutting conditions.Pho
to c
ou
rtes
y o
f Sa
ndv
ik.
“The big confusion is switching back and forth from inch to metric and back,”
McBride notes.
He agrees that machines are more accurate in the metric mode because most
machines today are manufactured to metric standards—including the controls.
“Most of the company’s new tooling is developed in metric first and then later
made to inch standards,” explains McBride.
Over at Ingersoll Cutting Tools, William Fiorenza, Product Manager, Die &
Mold, says the company recognizes the metric trend by offering tooling in both
inch standard and metric. In the last 10 years Fiorenza has seen the metric stig-
ma continue to dwindle. “As a cutting tool supplier, customers frequently like to
take a tool for a test drive (test the tool out). Oftentimes, in the North American
market testing was performed with inch standard diameter tooling at the request
of the customer; however, in more recent years customers seem to be much
more willing to test metric tooling.”
He attributes this to metric tooling being available where the inch version
is not a change in internal shop culture, policy or standard; and, seeking
increased sales through other markets that have adopted the metric system as
their standard thereby requiring their vendors and suppliers to use the metric
system as well.
Fiorenza continues, “One
additional tie-in that I
believe is advancing further
acceptance of the metric
system is the many advances
in CAD and especially CAM
over the years. I believe the
advances in CAM software
along with a better edu-
cated workforce (those that
excel in manufacturing/
programming) have helped
to encourage the use of any
tooling that can bring about
productivity gains.”
He also believes CAM
systems now very easily
convert units and simplify
the implementation of met-
ric cutters, which is true if
the mold/die is designed
in inch or metric. “More
programmers are also see-
ing advantages when using
a metric diameter cutter on
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Components, Software, Machining, Measurement
38 MoldMaking Technology October 2013
a mold/die that was designed in inch. For instance, a shallow
mold cavity or core (features) that was designed with 0.500
inch fillets. A 12 mm (.472") diameter tool will allow for a
more free cutting action being able to swing the corner. This
is sometimes also referred to as rolling through the
cut/corner.”
He explains that the metric cutter combined with high-
speed machine features within a CAM system enhances cutter
performance by creating better cutting conditions. “Constant
uniform chip load is one benefit that is a result of implement-
ing a metric cutter in the situation previously mentioned and
this does increase tool life,” states Fiorenza.
Sandvik Coromant offers 70 percent metric to 30 percent
inch, and has seen an 8 to 10 percent increase in metric orders
over the past 3 to 5 years, according to John Dotday, Product
and Application Specialist.
As a global tooling company, Sandvik Coromant needs to be
highly flexible while continuously working on turn-key proj-
ects with their machine tool partners for which the machine/s
will be shipped to another market. For many of these projects
it is extremely important that they have a vast assortment of
both metric and inch, and also have the programming support
from the machine tool builders to program the part dimen-
sions in either inch or metric.
“Over the past 10 to 15 years we have seen a big change in
the global marketplace with manufacturing companies looking
to expand their operations in other markets. The foreign auto
manufacturers have built several large manufacturing facili-
ties here in the U.S. bringing with them CNC mills and lathes
already tooled and programmed to manufacture parts. Visiting
these plants you will see extensive use of metric tools and
CNC programs with metric dimensions.”
6. Measurement
With the part finally produced, it needs to be measured and
inspected. For most of the standard tools it makes sense to buy
new metric micrometers, etc. Everyone is aware that tools with
electronic displays can toggle between inch and metric. When
it comes to inspection and measurement with gages it is a bit
more complex.
George Schuetz, Director of Precision Gages at Mahr Federal
notes that switching to metric for any company can be a
daunting undertaking. “The world is demanding it from U.S.
manufacturers, but there are many levels of switching over to
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moldmakingtechnology.com 39
cOntributOr
David Frost is manager of Frost Technical Concepts.
For more inFormation:
Delcam / delcam.com
Edro Engineering & Specialty Steels / edro.com
Frost technical concepts, LLc. / (413) 329-8630
[email protected] / frosttechnical.com
GFAgiecharmilles / gfac.com/us
HAScO canada inc. / hasco.com / hascoshop.com
ingersoll cutting tools-Member iMc Group / ingersoll-imc.com
Mahr Federal / mahrfederal.com
Mastercam / mastercam.com
Okuma America corporation / Okuma.com
OSG tap & Die, inc. / osgtool.com
Ptc/ ptc.com
Sandvik coromant co / sandvik.coromant.com
Siemens PLM Software / siemens.com
Solidworks corp. / solidworks.com
make metric products and the one to choose depends on his-
tory, cost and the capability to speak multiple languages (inch
and metric).”
Existing gages do not need to be replaced. New gages can be
built to metric sizes if that is what is required.
Summary
Changing to metric should not be a big challenge, according to
the arsenal of advice shared here. CAD and CAM can handle
it—and even allow you to go back and forth from inch to met-
ric while also telling the machine whether the program code
is inch or metric. Many machining centers are typically more
accurate when they are running in metric mode, and there is
plenty of support for gages and measurement in metric. Most
of the information we have presented here supports the metric
change. As more American shop owners take a look and under-
stand what is involved, they will make the change to metric.
Note: For each of the categories examined here there are
numerous suppliers, well beyond the ones who were able to
participate in this article. For those not included and interested
in providing some comment, please contact the editor.
www.usuniontool.comU.S. Union Tool, Inc
1260 N. Fee Ana St, Anaheim, CA 92807
Tel:1 (714) 521 6242 Fax:1 (714) 521 8642
What’s in your collet?....
Is a great question!
More U.S. mold makers than ever are answering
“Unimax by Union Tool.” - Why?
They prefer the winning high performance of
the Unimax series end mills, with their class
leading tolerances and durable coatings,
all supported by a nationwide service network,
with fast, reliable supply.
Ask us if Unimax is right for you!...
Mold Design By Doug Hepler
Mold Cooling OptionsA look at three options for integrating conformal cooling
into a core or cavity with an emphasis on vacuum brazing.
Figu
res
cour
tesy
of
Poly
shot
Cor
pora
tion
.
Two examples of mold cores used to produce a molded cap. Left one is
cooled with a typical baffe with the cooling coming up through the center of
the core, and the right one is a core with the exact same external dimensions,
but with conformal cooling employed.
40 MoldMaking Technology October 2013
Figure 1
Much has been written and discussed relative to the cool-
ing of mold cavities. Most molders and moldmakers are
at least aware of the benefits of placing as much heat
removal technology into a mold core or cavity as possible. Simply
drilling a hole into the bottom of a core for a closure and insert-
ing a baffle or bubbler results in uneven heat. This heat must
be lowered in the core to a temperature before the part can be
safely ejected. This uneven heat results in a poorly cooled core,
and a longer cooling time that is both wasteful and expensive.
As the technology has evolved for computer simulation of
the injection molding process,
molders are able to understand
more of the science behind what
is actually happening during the
cooling process of the mold-
ing cycle. This becomes read-
ily apparent when the molder
understands what his product
actually is: It is not simply the
sale of a quality plastic part, but
is actually the sale of his machine
time. To state it as simply as pos-
sible, the product is cycle time. The more parts that can be pro-
duced to the customer’s specifications within a given period of
time, the cost to produce each part is reduced.
enter Conformal Cooling
Conformal cooling is a technique to get cooling lines as close to
the surface of the molded part as possible. Moving the cooling
lines closer to the part being molded, results in a shorter cycle
time and a more uniform cooling of the molded part surface.
There are several options for integrating conformal cooling
into a core or cavity.
1) Direct Metal Laser Sintering (DMLS): This is a process
in which a core or cavity is built up in layers using a laser
that builds the core or cavity up slice by slice. This is an ideal
method when cores or cavities are a smaller size because the
powdered metal is quite expensive.
2) Heat/Pressure: Another process to form internal cooling
lines, which uses heat and pressure in a vacuum furnace to
bond plates together. This process employs physics that occur
when two pieces of steel are touching under heat, hydraulic
pressure and vacuum. Essentially molecules jump the gap
between the materials being joined and link together. The
main limitation of this process is high cost and a joint that is
not nearly as strong as the base materials being bonded.
3) Plate Fusion Technology: This is a variation of the sec-
ond process option. It still uses heat and vacuum to fuse two
or more plates of steel together, but the difference is there is
now a filler metal that is used between the plates—there is no
filler metal in the previous bonding process. This process also
reduces the cost for each part to be produced because it does
not require centering the plates being fused to be located over
a single hydraulic pressure source while in the furnace.
This technology was developed and refined by several pro-
ducers of hot runner manifold systems for creating internal
It is not simply the
sale of a quality
plastic part, but is
actually the sale of
his machine time.
moldmakingtechnology.com 41
Mold (Core) Tempera-
ture at End of Cooling
Phase: At the warmest
place on the cores, the
temperature dropped
from 245.5°F to 118.5°F,
which translated into a
39 percent reduction in
cycle time.
Part Temperature at
End of Cooling Phase:
Dropped from 149.8°F
to 93.8°F, a 38 percent
reduction on temperature.
Figure 2a
Figure 3a
Figure 2b
Figure 3b
flow paths in hot runner manifold systems. It resulted in these
manufacturers being able to place internal flow paths any-
where within any matrix of steel, in three dimensions while at
the same time being able to withstand extremely high internal
pressures.
Over time, customers of these hot runner manufacturers
started to request that their cores and cavities be produced
by the same method. The benefits of extremely high bond
strength with the plate fusion process are helpful in confor-
mally-cooled mold core and cavity construction. It results in
cores and cavities that are able to easily resist water leaks over
time by the external pressures created in the injection and
cooling phases. It resists leaks because of the extremely high
bond strength, which is the result of this particular form of
bonding versus others.
This process also allows the fusing of all the typical mold
steels—420 stainless steel, H13, S7, P20, etc. These steels are
also able to be fused to a copper-based material for a hybrid
assembly if needed. After plate fusion is completed, the fused
assembly can be annealed, heat treated, etc. as any other typi-
cal mold core or cavity.
This allows moldmakers to work with the steels they are
used to. Grinding, milling, wire and ram EDM processes are
performed just as they normally would be. The main differ-
ence is they are done with the fused assembly with the inter-
nal flow passages intact. All finish machining is done after the
fusion process is complete.
Case in Point
Figure 1 image (page 40) shows two typical examples of the
mold cores used to produce a molded cap. One is cooled with
a typical baffle with the cooling coming up though the center
of the core. The second example is a core with the exact same
external dimensions, but with conformal cooling employed.
The example part being molded is a polypropylene molded
cap, center gated with a pinpoint style hot runner system. An
analysis was performed on both the baffle and conformally-
cooled core. The study included determining several factors that
have an effect on the cycle time of the part as well as part quality.
Findings
Baffle versus conformal core with plate fusion (see Figures
2-5): Part Temperature at End of Packing Phase: Dropped from
165.7°F to 106.3°F, a 36 percent reduction in temperature. Part
Temperature at End of Cooling Phase: Dropped from 149.8°F
to 93.8°F, a 38 percent reduction in temperature. Mold (Core)
Temperature at End of Cooling Phase: At the warmest place
on the cores, the temperature dropped from 245.5°F to 118.5°F,
which translated into a 39 percent reduction in cycle time.
Also very interesting were the results on part warping. The
Mold Design
42 MoldMaking Technology October 2013
total displacement warpage was reduced
25 percent on the conformally-cooled
core with all effects included.
Summary
The use of conformal cooling is a win for
everyone involved. The moldmaker sells
more molds because he has a happy cus-
tomer; the molder makes more parts per
hour and the customer gets a better quality
part at a lower cost. Using the best method
for each particular application to produce
the conformally-cooled cores and cavities
will result in satisfied customers.
For more inFormation:
Polyshot Corporation
(800) 765-9746 / polyshot.com
Shadow Polymer Industries
(281) 789-7520
shadowpolymer.com
COntrIbutOr
Doug Hepler is president of Polyshot Corporation,
and Rob Hickman is president of Shadow Polymer
Industries.
Part Temperature at
End of Packing Phase:
Dropped from 165.7°F to
106.3°F, a 36 percent
reduction on temperature.
Total displacement
warpage was reduced
25 percent on the
conformally-cooled core
with all effects included.
Figure 4a
Figure 5a
Figure 4b
Figure 5b
EDM
44 MoldMaking Technology October 2013
Integrating Electrode Production
By Thiago Fagionato
The production of electrodes is a key stage in the manu-
facture of many types of tooling, including injection
molds, so the availability of a faster, more automated
method for their development will increase efficiency and
reduce leadtimes across a number of industries. Here is
where CAD/CAM comes into play.
Can you imagine a CAD/CAM file format that enables the
design, machining and inspection of electrodes to be com-
pletely integrated? Well, if it exists that file would need to
contain all of the information developed during each elec-
trode project—including not only the electrode design, but
also the machining and inspection information, as well as the
setup sheets and scripts. Then all of this required informa-
tion would need to be in a single file to simplify data man-
agement as well as increase overall efficiency.
Here is what to look for in this type of a CAD/CAM solu-
tion for electrode production integration:
The first step in creating the file would come during the
initial design stage of electrodes. The design software would
allow users to quickly and easily define the region where the
electrode will be used; extract the shape needed to produce
the required feature in the part; and then, edit the design to
provide clearance from the main surface of the tool and to
blend it into the blank size needed to fix the electrode into
its holder.
Design software usually includes analysis tools to check
that the draft angles and minimum radii used in the design
will not cause downstream problems, but on top of that
would be the ability to simulate the action of the electrode
on the computer, which ensures it will operate as expected
on the EDM equipment.
How CAD/CAM can help make
the design, machining and
inspection of electrodes
completely integrated.
Video
Access video
at end of article.
moldmakingtechnology.com 45
cOntributOr
Thiago Fagionato has worked for Delcam for 10 years. He started his career at
Delcam headquarters in Birmingham, UK, and now resides in Windsor, Ontario
where he works as Senior Applications Engineer for Delcam North America.
To speed the design process further, catalogs of blanks and
holders from leading suppliers should be included in the soft-
ware, but users should also be able to add their own standard
sizes to these databases.
Once the design has been
finalized, the information in
the data file would need to be
extended to include the spark
gaps necessary to provide the
offsets required in the machining
software that will be used to cut
the roughing and finishing elec-
trodes. Inspection points would
also have to be added, so that the
measurement of the machined
electrode could be automated
to a large extent. In addition,
setup sheets for the electrode’s
manufacture and use should be
produced automatically—either
to a standard format or to a user-
defined template.
Companies that produce
multiple electrodes of similar
sizes from the same material will
find it worthwhile to develop
templates within their CAM pro-
gramming software to machine
them in a standardized way. Your
CAD software should automati-
cally color-code burn, clearance
and blank faces of the electrode
during the design stage, so that they can be recognized
within the machining software. The size of the material
block and the spark gaps for the electrode family should also
be incorporated into the project data file and applied to the
toolpaths automatically. Once the templates have been cre-
ated, generating the machining toolpaths should become a
fully-automated process.
This automation will save considerable time for the user;
however, when machining a large number of electrodes, it
is inefficient to wait for toolpaths to be calculated on each
individual project. To overcome this problem, applying
batch processing to multiple projects is necessary. With this
approach, processing the toolpaths starts as soon as the first
project is loaded.
Subsequent projects displayed in a list with calculations
beginning on the next item in the list automatically is ideal.
If the calculations for a particular electrode cannot be com-
pleted—for example, if the system detects a collision—the
problem should be recorded and the software should move
on to the next item automatically. Thus, a long series of cal-
culations can be left to run overnight if necessary.
Specifying the inspection points within the file during
electrode design means that the probe path for the inspection
and the production of the inspection report will be automat-
ed—including undertaking a best-fit analysis of the machined
electrode. The results of the inspection need to be able to be
added to the project data file for quality control records.
Scripts are the EDM equivalent to CAM programs for
machine tools. They provide an automated process for the
programming of the machine, instead of users having to pro-
gram manually from a setup sheet. The automated process is
much easier and quicker, especially when a number of elec-
trodes are being used on the same component. In addition,
the direct link removes the human error that could always be
possible with manual programming.
The automated generation of setup sheets would need to
be possible for both the machining and application of the
electrodes to ensure that all the data needed at each stage
is readily available. A documentation pack, including the
GA and detail sheets, would need to be generated in various
formats—such as drawings, HTML files or Microsoft Excel
spread sheets. All these options are important to allow easy
communications between the various people involved in the
design, manufacture and use of the electrodes.
VIdEo: Increasing Electrode Effciency at Cavalier Tool & Manufacturing http://short.moldmakingtechnology.com/ cavalier
For MorE InForMaTIon:
Delcam / [email protected] / delcam.com
Imag
es c
ourt
esy
of D
elca
m.
TOP IMAGE: An integrated system for the design, machining
and inspection of electrodes.
IMAGE TO LEFT: The production of electrodes is a key stage in the manufacture
of many types of tooling, including injection molds, so the availability of a faster,
more automated method for their development will increase effciency and
reduce leadtimes across a number of industries. Currently, the design, machining,
inspection and use of electrodes are undertaken as separate activities. Closer
integration of these key stages into a single workfow, based on a single data fle,
would offer a faster, more reliable and more productive process.
Supply Chain Management
46 MoldMaking Technology October 2013
By Paula Hynes
Mold manufacturers and molders alike should always
continue to assess—and invest in—the latest technol-
ogy. Not only can the effective use of automation and
robotics result in lower long-term production costs, but mold-
makers who offer molding capabilities can provide sample/
tryout services and perhaps even evolve into single-source pro-
viders, enabling earlier project involvement and control of the
manufacturing process.
Here at The Rodon Group, we recently added six of the
latest Nissei servo-driven hydraulic machines. These energy-
efficient machines provide the combined advantages of both
hydraulic and electric injection systems; and are designed to
deliver better performance for both thin- and thick-walled
applications.
With this in mind, here are some injection press basics that
will give you a better understanding of the presses, processes
and pitfalls in the molding industry.
To determine the size of the machine needed to get the best
results, a project designer or engineer can get a good estimate
based on some basic information. By knowing approximately
what size machine will be required, you can better source a
plastic injection molder to source the work to or you can pur-
chase a machine for your shop.
Plastic Injection Molding Press Classifications
A general molding equipment list may look something like
this:
• 3-68 ton injection molding presses
• 5-123 ton injection molding presses
• 5-154 ton injection molding presses
• 5-202 ton injection molding presses
• 5-233 ton injection molding presses
• 4-400 ton injection molding presses
So, what does this mean?
Maximizing the Manufacturing Process with an Injection Press
Minimize the overall costs of your customer’s project
with the addition of a press.
Pho
tos
cour
tesy
of
The
Ro
don
Gro
up.
™
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 Value“Big 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 refl ects that
of our own mission goals.
We’ve chosen EDRO’s 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
fi eld as well as improved effi ciencies during manufacturing.
We’ve 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 EDRO’s RoyAlloy™.”
Scott Gibson Plant Manager, Big 3 Precision Products, Inc.
RoyAlloy™ Stainless is covered under Patents 6,045,633 and 6,358,334
Supply Chain Management
48 MoldMaking Technology October 2013
Plastic injection molding presses are classified or rated based
on tonnage, or more specifically the clamping pressure or force.
Presses can run in size from less than 5 tons of clamping pres-
sure to over 4000. The higher the press ton rating, the larger
the machine.
A machine rated for 68 tons can deliver 68 tons of clamping
pressure. This pressure keeps the mold closed during the injection
process. Too much or too little pressure can cause quality issues.
Too much or too little pressure can also cause flashing, where excess
material appears on the part edge. Pressure also impacts the viscos-
ity of the plastic being used in the project. Melt Flow Index or
MFI is a measure of the ease of flow of the melt of a thermoplastic
polymer. Plastic compounds react differently to pressure based
on their MFI. The higher the MFI, the higher the pressure needed.
cOntributOr
Paula Hynes is the Communications Coordinator for The Rodon Group, one of
the largest family-owned plastic injection molding companies in the U.S. Her
writing focuses on the plastic injection molding industry, U.S. manufacturing
and STEM education. She has more than 30 years of experience in marketing
and communications.
For more inFormation:
the rodon Group / (215) 822-5544
[email protected] / rodongroup.com
View additional blog articles at info.rodongroup.com
Learn moreVisit our Business Strategies Zone for more information about
the management issues facing today’s mold shops, including sales
& marketing, global initiatives/strategies, banking and fnance,
workforce development and new business opportunities.
Go to moldmakingtechnology.com/zones for a complete list.
How Do You rank When it Comes to Supplier relations?
This past July an industry survey conducted by Tech Molded Plastics, Inc.
(Meadville, PA; ttmp.com) of OEMs and suppliers in the automotive, medical,
electronics and aeronautics industries revealed the most valuable supplier
characteristics that key industry players would like to see in a supplier of
precision molded plastics.
Notable fndings in-
clude the importance on
quality over price. The top
three areas of importance
identifed were Long-term
Quality of Products/Molds,
Initial Quality of Products/
Molds and On-time Delivery
of Product; and, by a wide
margin, the least impor-
tant aspects were Pricing
of Product, Quote Response
Time and Total Life-cycle
Cost Performance.
Respondents were also
asked to identify aspects of the injection molding industry that cause them
pain within their areas of responsibility—for example, issues arising from
a lack of deep understanding in the construction of tools; managing low-
cost supplier decisions from an engineering standpoint; and, fnding quality
suppliers who are willing to do the little extra to make sure it is done right.
Overall, this industry survey shows that OEMs have high expectations
for suppliers, and that suppliers who incorporate the needs of OEMs for
strategic planning purposes are able to competitively position high-value
services to achieve steep expectations.
ViDeo: a Quick tour moldmakingtechnology.com/videos/ a-quick-tour
Clamping Force/Pressure requirements
There are many factors that are taken into consideration when
determining the size of the press. The size of the part, the
polymer being used and something called the safety factor. The
safety factor is an additional numerical percentage buffer that is
added to the calculation to help avoid defects in the final part.
Some recommend adding 10 percent to allow for the safety fac-
tor. As mentioned earlier, the MFI (Melt Flow Index) of the plas-
tic compound will also impact the pressure needed to produce
the part. Many calculations include the platen size as well as the
mold and part size; however, to get an estimate of the press size
your project will need, we have simplified it even further.
Many plastic injection professionals use a general rule of thumb
of 2.5 times the surface square inches of the part to be produced.
So, if you have a part with 42 square inches than you would need
a press size with 105 tons of pressure. If you add 10 percent for
a safety factor, you will need to use a press with a minimum
of 115 tons of clamping force. A press size of 120 tons would be
able to accommodate your plastic injection molded product.
a Lasting investment
Once you have an estimate of the press size you will need, you
can contact injection press manufacturers and/or distributors
who can guide you through a purchase. Larger presses can
accommodate larger molds and multi-cavity molds—often
reducing the cost per part. However, larger molds are more
expensive. Choosing the right press size can balance the upfront
tooling expenditures with long-term manufacturing costs.
Phot
o co
urte
sy o
f Te
ch M
olde
d Pl
asti
cs, I
nc.
Our Unitized Systems have over a decade of reliable use globally in a wide range of applications. Customers have benefi tted
from the added value of our “Ready-to-Connect” system with simplifi ed integration and quick start-ups. Add in our
Leak-Proof design for maximum productivity, and you have an unbeatable combination. That's INCOE® Hot Runner Performance.
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I DFQ Threaded Nozzle-to-Manifold Design
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INCOE® Corporation
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T: +1 (248) 616-0220
F: +1 (248) 616-0225
North America | Europe | Asia | South America
www.incoe.com
Visit us at booth
#1B09
50 MoldMaking Technology October 2013
Product Focus
Bridge-Type VMCYama Seiki Bridge-Type LP series VMC features a high speed, high torque
8,000 RPM built-in motorized spindle; and is designed to provide cutting flex-
ibility for various working condition. The X-axis is supported with two linear
guide ways and two box ways which provide high rigidity structure, the com-
pany states. The Y-axis is supported with two linear guide ways and the Z-axis
is supported with two box ways to enhance the movement and precision. The
X-axis ball screw is placed in the center of the axial movement to provide high
precision axial feeding features—and to avoid movement yawing problem and
guide ways’ uneven wear-out. The ball screw vibration absorber reduces the
vibration and increase the accuracy.
The LP series can be equipped with the AWEA-manufactured, 8,000 RPM
built-in spindle which provides maximum of 440 ft-lb torque output at 350
RPM. The built-in motor design reduces centrifugal force effect and restrains
spindle vibration. It can successfully increase the spindle life span and
improve the machining accuracy. The floating type hydraulic tool release
device can eliminated pressure on the spindle bearing.
For more information from Yama Seiki USA, Inc. of Chino, CA,
phone 909-628-5568 or visit yamaseiki.com
Indexable Milling InsertThe ISCAR products of the latest HIGH QLINE family of cutting tools offer an
interesting solution to the chatter or vibration in metal cutting that poses
an eternal challenge for manufacturers: “Indexable Milling Insert with an
asymmetric shape”. This insert opens up new opportunities for reduction of
vibrations in metal cutting, the company states.
The design of the new one-sided insert HM90 ADCT 1505 ...-CF follows a
different and unique approach compared to traditional milling inserts in the
market, the company states. The insert has different helix angles on the two
cutting edges and the two edges are colored gold and black. The concept is to
mount gold and black edges alternately resulting in variable helix configura-
tion for the cutter.
This feature ensures significant improvement of the cutters’ performance
in shoulder milling by reducing vibrations. Typically, the tool life of the insert
increases by 15 to 20 percent and the power consumption is reduced by 10
percent or more. This solution is suited for less rigid set-up, long overhang
applications, thin-walled work pieces
and problematic work holding, etc. The
company adds that these inserts are
also suitable for already existing cutters
as well as the Heli-Mill Family of milling
cutters.
For more information from
Iscar Metals, Inc. of Arlington,
TX, phone 817-258-3200 or
visit iscarmetals.com
Diagnostics/Evaluation/Education/RepairThe latest brochure from Stateline Services Division features
a wide variety of products and services—including all phases of
machine tools, accessories, tooling and gauging. Additionally, the
company offers seminars tailored to one’s shop and requirements.
These courses will give employees the tools they need to succeed
on the job, and enable them to build on the knowledge they already
have. SSD offers on or off-site classes, on any shift, and for any
number of people. All required equipment and materials provided
at no additional charge. Complete off-site packages are offered,
which include hotel, transportation, meals, and all related items.
All programs and seminars are conducted by shop floor veterans
who are acknowledged experts in their field, the company states.
The company also offers full-service repair for all major machine
components, including vibration analysis, new spindles, com-
plete spindle repair, toolholders, power drawbar service, gauging
evaluation, machine rebuild projects, cutting tools and angle heads.
Additionally, the company specializes in HSK products.
For more information from Stateline Services
Division, LLC of Sharon, WI, phone 262-736-2205
or visit hsk-america.com
Core Metrology Gauging GuideBlum LMT, Inc. has introduced a Gauging Guide—a graphical user interface
(GUI) developed to complement many of Blum’s core metrology products,
including lasers, tactile tool setters and workpiece probes. The GUI makes the
use of Blum’s core products extremely easy for operators and programmers,
and was developed for use on Okuma THINC Series controls. Unlike other
metrology equipment GUIs, Blum’s Gauging Guide is the only one that cur-
rently utilizes Okuma’s THINC API, allowing operators to take advantage of the
integration between the Okuma THINC control and Blum’s Gauging Guide with
a simple one-touch of the screen, the company states.
Blum began development of the new software after realization that some
of the advanced features of Blum’s products were not being utilized due to
the programming knowledge that was required. Blum’s product software offers
many advanced measurement capabilities to users. The Gauging Guide utilizes
these advanced measuring capabilities in the macro programming software by
channeling access to advanced programs through a clean and straightforward
graphical user interface.
For more information from BLUM LMT Inc. of Erlanger, KY,
phone 859-344-6789 or visit blumlmt.com
52 MoldMaking Technology October 2013
Product Focus Product Focus / Hot Runner / Material
Nozzle TipsINCOE Corp. has introduced two new products for
nozzle tips, emphasizing improved color changes
and optimization of engineered resins. The HT
nozzle tip was specially designed for demanding
engineered resins, particularly for processing at
high temperatures. The Torpedo is centered in
the hot runner gate and is held from behind by
crosspieces so that the melt can exit into a central
ring channel. Heat conduction is symmetrically led
up to the exit point. The torpedo tip can ensure a
small vestige height. This new product gives customers the benefit of the INCOE concept of maximum
modularity: the HT nozzle tip fits in the end cap of the ST tip and is easy to replace if needed.
The new VIX nozzle tip for valve gate nozzles makes considerable improvements for color changes,
the company states. The modifications in geometry permit a reduced time between color changes, as
numerous customer trials have confirmed. An additional application use is for materials that are later
plated. The VIX nozzle tip is suitable for hydraulic and pneumatic systems alike.
For more information from Incoe Corporation of Troy, MI, phone 248-616-0220 or
visit incoe.com
Powder Metal Tool SteelDiehl Steel stocks and sells a wide variety of grades of CPM powder metal tool steel. The CPM process
produces more highly alloyed grades of steel which cannot be produced by conventional steelmaking,
the company states.
Diehl Steel offers a range of grades: CPM 1V®, a medium-carbon, powder metal tool steel that exhibits
high impact toughness; CPM 3V®, an air-hardening, powder metal tool steel with a unique chemical com-
position that results in tooling with a combination of high impact toughness and wear resistance; CPM
9V®, a powder metal tool steel that provides high wear resistance in combination with impact toughness;
CPM 10V®, a versatile air hardening, powder metal tool and die; CPM 15V®, a powder metal tool steel with
exceptional wear resistance; CPM REX M-4®, a powder metal tool steel that offers improved cutting tool
life; CPM REX 76®, a super high speed steel that contains high carbon, vanadium and cobalt for abrasion
resistance; CPM REX T15®, a tungsten type super high speed steel containing high vanadium for abrasion
resistance; CPM REX 45®, an 8 percent cobalt super high speed steel which has excellent hot hardness.
For more information from Diehl Steel Co. of Cincinnati, OH, phone 513-242-8900
or visit diehlsteel.com
Two-Speed Sequential Valve GatingSynventive Molding Solutions SynFlow® two-speed sequential valve gating hot runner technology
provides molders with optimized plastic flow control, and solves common surface defect problems on
large parts such as automotive bumpers and instrument panels.
All of Synventive’s Advanced Flow Control hot runner systems (eGate®, Dynamic Feed® and SynFlow®)
are designed to provide molders with more control over the molding process to produce parts with higher
quality surface finishes. SynFlow® is a patent-pending, two-speed pin control technology for cascade or
sequential valve gated hot runner systems. The initial opening speed of the valve pin is reduced to pre-
vent an explosive rush of pressurized plastic. The valve pin then opens for the remainder of its stroke at
maximum speed to appropriately fill the part.
For more information from Synventive Molding Solutions of Peabody, MA, phone
978-750-8065 or visit synventive.com
Phoenix Laser Solutions, Inc.
814-724-3666www.phoenixlaser.com
• LASER WELD
• LASER ENGRAVE
• WATERJET CUTTING
• LASER SYSTEM SALES• LA
The Largest Laser Welding Repair Company in North AmericaThe Largest Laser Welding Repair Company in North America
SERVING THE TOOL, DIE & MOLD INDUSTRY FOR 30 YEARSSERVING THE TOOL, DIE & MOLD INDUSTRY FOR 30 YEARS
We do whatever it takes to ensure
EXCELLENT
TurnaroundPricingQuality
✓
✓
✓
USMWA of NC
Mount Holly, NC Phone: (828) 429-0736
Phoenix Laser Solutions
Meadville, PA Phone: (814) 724-3666
www.alphalaser.de
ALPHA LASER GmbH
Munich, GERMANY Phone: +49 89 890-2370
The inventors of
mobile laser
welding
Powerful laser welding machines
Flexible, highly efficient, easy to use
Over 20 years of experience in laser technology
When Flexibility Matters … OUR EXPERIENCE FOR YOUR SUCCESS
You will feel the difference!
54 MoldMaking Technology October 2013
Product Focus Product Focus / WESTEC October 15-17, 2013, Los Angeles Convention Center
Advanced ToolingToolholding innovation will take cen-
ter stage in the REGO-FIX booth 1832 at
WESTEC 2013. The company will present
its new low-cost retrofit solution for the
internal cooling of driven tools as well as
showcase advanced tooling systems that
bring precision, strength and ease of use
to demanding part machining applications.
Show attendees seeking an affordable,
low-maintenance solution for extending the
tool life of their milling cutters and drills
should check out REGO-FIX’s new reCool
cooling system. reCool allows manufacturers
to retrofit their driven tools to be able to
benefit from internal or peripheral cooling,
which is much more effective in getting cool-
ant to the cutting edge when compared to
spray pipes or nozzles, the company reports.
For more information from REGO-
FIX Tool Corp. of Indianapolis,
IN, phone 317-870-5959 or visit
rego-fix.com
Surface Finish Measurement for CMMsIn Booth 1600 at WESTEC 2013, Renishaw will show its SFP1 probe
option for the REVO® five-axis measurement system—the first to
allow surface finish inspection to be fully integrated within coordi-
nate measurement routines, the company reports.
With a measurement capability of 6.3 to 0.05 Ra, the SFP1 surface
finish probe makes the CMM a “single platform” metrology system.
It eliminates the need for hand-held surface measurement devices
or transporting parts to a dedicated surface measuring machine,
reducing labor costs and inspection leadtimes, according to the
company.
The SFP1 probe is a fully integrated option for the REVO five-axis
measurement system, supplied with two dedicated styli, straight
and cranked, which are selected via the measurement program
control using the system’s modular rack system (MRS). The probe
incorporates a C axis that, combined with the infinite positioning
of the REVO head and choice of stylus holders, allows the probe tip
to be automatically oriented to any angle to suit the part, ensuring
that the highest quality surface data is acquired.
For more information from Renishaw Inc of Hoffman
Estates, IL, phone 847-286-9953 or visit renishaw.com
In its 12th year, the Leadtime Leader Awards,
presented by MoldMaking Technology, honors
those outstanding North American mold
manufacturers who best demonstrate overall
innovation, effciency, quality and commitment
within their moldmaking operations while
raising the bar in terms of mold engineering,
building, repair and management.
Nominate Your Shop Today!
”Often we are so focused on the day-to-day activities of running
a business that we don’t think much about all of the things that
we’ve done over the years to create and sustain a successful
business. In retrospect, flling out the Leadtime Leader Award
questionnaire forced us to consider all the various components
of our success including the adoption and implementation of new
technologies, customer service, continual education, training
and cross-training of employees, our sales/marketing efforts, and
involvement in our industry in ways that help to make it better
and stronger. We believe that receipt of the Leadtime Leader
Award is recognition from our peers of a ‘job well done’ and we
want to thank everyone involved in the process.”
Jerry Seidelman, Tech Mold, Inc. — 2013 Leadtime Leader Winner
For complete information, eligibility requirements and nomination forms,
please visit: short.moldmakingtechnology.com/LLA
or contact Editorial Director Christina Fuges at [email protected] or (800) 579-8809
Innovative / Effcient / Quality-Driven / CommittedIf this describes your shop, then you have what it takes to be a leader.
SponSored by:
preSented by:
Winner and Honorable Mention Rewards:
A full cover feature with video on your shop
in MoldMaking Technology magazine and online
Free expanded showroom on MoldMakingTechnology.com
and on PTonline.com
Complimentary 10’ x 10’ booth as well as 2 complimentary
full conference registrations for amerimold 2014 –
June 11-12 at Novi, MI’s Suburban Collection Showplace.
www.amerimoldexpo.com
Winners earn a targeted advertising program in
Plastics Technology magazine (ptonline.com) to market
their products and services to more than 25,000 molding
subscribers at more than 11,600 molding facilities!
¥ Gain industry recognition and build brand awareness
¥ Attract new customers
¥ Boost morale in the shop
¥ Distinguish your shop as an industry leader
56 MoldMaking Technology October 2013
Product Focus
Engineered Coatings and Finishes – Since 1978 –
ISO Certifed / Woman Owned Business
(800) 215-6653
www.balesmold.com u [email protected]
uDiamond Chrome
uHard Chrome
uNibore®
uNicklon®
uElectroless Nickel
uDiamond Polishing
uPassivation
uMicro T.I.G. Welding
uBlasting
uPocket S.P.I. Finish Guide
uX-Ray Certifcations
uPick up & delivery available
Product Focus / WESTEC
Versatile Dual-Spindle, Y-Axis Turning CenterAt WESTEC 2013 in Booth 2312, Haas will show the Haas DS-30SSY turning cen-
ter, which combines dual-spindle turning with Y axis, C axis, and live tooling to
create a powerful “done-in-one” machining solution for any shop. The opposed
spindles support fully synchronized turning, and allow on-the-fly part pass-off
to reduce cycle times, the company states. The machine comes standard with
high-torque live tooling and a servo-driven C axis, and provides 4” of Y-axis
travel (±2” from the centerline) for off-center milling, drilling and tapping.
The Super Speed DS-30SSY has a maximum cutting capacity of 16” x 23”
and is equipped with a 24-station hybrid BOT/VDI turret. The A2-6 main spindle
features an 8.3” hydraulic chuck, and is powered by a 30 hp vector drive
system that provides 275 ft-lb of torque. The A2-5 secondary spindle also has
an 8.3” hydraulic chuck.
For more information from Haas Automation, Inc. of Oxnard,
CA, phone 805-278-1800 or visit haascnc.com
ENTERPRISES, INC.
Your Source For: Quality Hydraulic Cylinders,
Micro Injection Molding Machines,
Hot Runner Systems, Quick Knockout Couplers,
and Much More!
Hydrauliccylinders
NEW
IncludIng lockIng cylInders
Tel: 909.941.0600 • 800.432.6653 • Fax: 909.941.0190
Email: [email protected] • Website: www.albaent.com
V024CX Electric Actuator
V215CR Tie RodHydraulic Cylinder
MAX. PRESSURE: Up to 50 bar (725 PSI)
BORE SIZE: 32 to 63 mm
STROKE: 50 & 500mm (according to the bore size)
MAX. PRESSURE:
Up to 215 bar (3117 PSI)
BORE SIZE: 12 to 140 mm
STROKE: 20 & 1500 MM (according to the bore size)
High Speed Machining/MTM ImprovementsIn Booth 3012 at WESTEC 2013, Gibbs and Associates will demon-
strate GibbsCAM’s High-Speed Machining (HSM) capabilities, including
GibbsCAM VoluMill, which enables milling cycles up to three times
faster, while simultaneously reducing tool wear. In GibbsCAM, VoluMill
maximizes material removal rates by generating toolpaths optimized
for the highest feed rates, using constant tool loading, and automati-
cally choosing the best option for individual pockets, including plunge
speed and material removal rates.
GibbsCAM’s powerful Multi-Task Machining (MTM) provides milling and
turning functions in a single interface, minimizing programming effort
to maximize programmer efficiency. A multi-task machine’s specific
configuration is automatically captured by GibbsCAM settings, with sup-
port for all utility operations available on the machine and its installed
optional equipment. GibbsCAM MTM supports an unlimited number
of tool groups, turrets and spindles, including those of Swiss-style
machines. The software enables elimination of multiple set-ups, greatly
improving part quality and production speed, the company notes.
For more information from Gibbs and Associates
of Moorpark, CA, phone 805-523-0004 or visit
GibbsCAM.com
moldmakingtechnology.com 57
October 15-17, 2013, Los Angeles Convention Center
High-Speed Machining CenterAt WESTEC 2013 in Booth 1325,
DATRON Dynamics plans
to demonstrate the M8Cube
high-speed machining center.
The M8Cube features brush-
less, direct drives that pro-
vide fast acceleration, feed
rates up to 866” per minute
and short cycle times. A 3kW, 40,000 RPM, liquid-chilled spindle delivers
greater horsepower for heavier machining, as well as the flexibility to
mill a wide range of materials. HSK-E 25 tool holders offer precision and
<1 micron run out. DATRON has positioned this model for precision, high
or low volume production of electronic, aerospace and medical parts,
as well as industrial engraving and micro-drilling applications.
DATRON will also be demonstrating the D5 Dental Mill by milling
titanium implant bars and abutments at the show.
For more information from Datron Dynamics of Milford,
NH, phone 603-672-8890 or visit datrondynamics.com
New Version of Simulation/Optimization SoftwareAt WESTEC 2013 in Booth 2147, CGTech will demonstrate the new version of
VERICUT® CNC machine simulation and optimization software. According to the
company, VERICUT 7.3 includes many enhancements that significantly improve
performance and further simplify the process of simulating a CNC machine.
Changes to how users interact with VERICUT further improve VERICUT’s work-
flow, and are a direct result of CGTech’s philosophy of continuous product
improvement.
VERICUT is CNC machine simulation, verification and optimization software
that enables users to eliminate the process of manually proving out NC
programs. It reduces scrap loss and rework. The program also optimizes NC
programs in order to both save time and produce higher quality surface fin-
ish. VERICUT is reported to simulate all types of CNC machine tools—including
those from manufacturers such as DMG-Mori Seiki, Mazak, Makino, Matsuura,
Hermle, DIXI, and Chiron. VERICUT runs standalone, but can also be inte-
grated with leading CAM systems such as Catia, NX, Creo Parametric (Pro/E),
MasterCAM, PowerMill, EdgeCAM, hyperMILL, Esprit and GibbsCAM.
The VERICUT user interface is very customizable. In version 7.3, the first
thing a user will notice is the all-new icons, available in multiple sizes. There
are also several user-selectable color themes.
For more information from CGTech of Irvine, CA, phone 949-
753-1050 or visit cgtech.com
System 3R USA LLC. 915 Busse Road, Elk Grove Village, IL 60007, Phone 847-439-4888, Fax 847-439-5099 e-mail: [email protected], web site: www.system3r.com
WorkPartner 1+
• Can serve one or two machines
• One, two or three magazine capability gives
exceptionally fexible capacity.
• Minimal foor space requirements.
modularly adapted to your automation needs
58 MoldMaking Technology October 2013
Product Focus
www.hasco.com
Toll Free 877-427-2662
HASCO –Together we shape your ideas !
Your global partner for all METRIC mold solutions
Product Focus / WESTEC October 15-17, 2013, Los Angeles Convention Center
Revamped CNC LineHurco will showcase its completely revamped line of CNC machine tools at
WESTEC 2013 in Booth 1920. The Hurco machines to be displayed include the
five-axis VMX30Ui, the performance VMX42i mill, the VM10i general purpose
mill, and the TMM8i mill turn lathe. All of the i series machines feature a sleek
design, new logo, and color palette that was introduced at IMTS 2012. However,
the most important asset of the newly designed machines is the inclusion
of UltiMotionTM in all three- and five-axis mills instead of it being an option.
UltiMotionTM is Hurco’s patented motion control system that has numerous
benefits including the ability to increase the quality of the surface finish while
reducing cycle time by up to 30 percent (or more depending upon the complex-
ity of the part), the company states.
The VMX42i (X/Y/Z travels of 42 x 24 x 24”) is designed from the ground
up to withstand the high velocities and accelerations of today’s applications.
It starts with a heavy, ribbed frame made of fine grain, high-grade cast iron.
The 12K dual-wound spindle provides more torque and the double-nut, pre-
tensioned ball screws are anchored at both ends for increased accuracy and
rigidity. The linear rails on all Hurco machines are larger, and spaced for
increased strength.
The VMX30Ui five-axis machining center has X/Y/Z travels of 30 x 20 x 20.5
and a 40-tool ATC. The benefits of a five-axis vertical machining center go
beyond simultaneous five-axis work. More shops are realizing greater profit
margins on existing parts by converting to a five-sided machining process
instead of using a conventional three-axis VMC. In fact, the majority of five-
axis machines are used for five-sided machining to reduce setup time and
eliminate the typical flipping of parts that is required on three-axis machin-
ing centers. Not only do shops increase the profit margin per part, they
increase accuracy when they switch from three-axis to five-sided machining,
the company states.
For more information from Hurco Companies Inc. of
Indianapolis, IN, phone 317-293-5309 or visit hurco.com
Workholding/Material Handling TechnologiesFixtureworks will showcase its extensive clamping, gripping, locating, posi-
tioning, roller, bumper and support products at Booth 3139 during WESTEC 2013.
The exhibit will feature the new urethane covered bearing rollers. Available
in stock, ready to ship with no lead time, no minimum order and no tooling
required, they are available in both inch and metric sizes. They have a smooth
urethane surface that is cast directly on a precision sealed ball bearing.
For more information from Fixtureworks of Fraser, MI, phone
586-294-1188 or visit fixtureworks.net
moldmakingtechnology.com 59
Search. DiScover. Select.
Search. PlaSPec Global allows processors, part
designers and oeMs to search for resins for existing
projects, choices for parts under development, and more!
Discover. Find the right material for your application in
the PlaSPec Global database.
Select. connect with the most qualifed suppliers via
PlaSPec Global and keep your projects moving forward!
PLASPEC Global offers the world’s most
current and comprehensive engineering data
on plastics materials and their applications.
Start searching and printing data sheets
from PLASPEC Global’s extensive database
of plastics materials and suppliers TODAY.
PLASPEC Global is presented through a partnership between Plastics Technology and the M-Base Materials Data Center. Plastics Technology is the leading U.S. publication and website serving plastics processors. M-Base is the leading international materials database and creator of the CAMPUS software.
Get started at PTOnline.com/plaspec
TIM Stack Mold UnitExhibiting at K 2013 in Hall 02, Booth A02, ZAHORANSKY will show a TIM Stack
Mold unit consisting of two mold halves with central rotary cube, allowing two
different parts to be made on a single mold. The special features of this new,
patented system are the two mounting platens outside the mold, allowing
complex mounting processes to be worked down outside the two mold halves
in the easiest possible way. The big advantage: the machine cycle is not made
any longer, the company states.
For more information from Zahoransky Formenbau GmbH of
Sugar Grove, IL, phone 630-466-1901 or visit zahoransky.com
Swiveling Hot Runner ManifoldsAt K 2013 in Hall 1, Booth A09, MHS-Mold Hotrunner Solutions has introduced
Rheo-Pro® Slide™ Manifolds, a revolutionary type of hot runner system with
rotating melt transfer joints that allow linked manifolds to move freely in
order to distribute plastic anywhere inside the injection mold, the company
states. The new technology now makes it possible to create injection points,
or gates, directly inside the slides of a mold. It also allows molders to create
continuous melt transfer connections that maintain contact, and therefore
flow, even when the mold plates separate.
The patent-pending hinge design allows its rotating joints to maintain a
constant seal while linking together multiple hot runner manifolds to create an
uninterrupted, continuous melt path that is
able to bend and move inside the injection
mold, the company reports. The technology
enables the melt channel to deliver material
to the cavity across moving mold elements
such as slides and lifters. Slide mechanisms
are the only way to demold complex parts
with exterior undercut side features.
For more information from MHS -
Mold Hotrunner Solutions of
Georgetown, ON, phone 905-873-
1954 or visit mhs-hotrunners.com
Product Focus / K Show October 16-23, 2013, Dusseldorf, Germany
Directories? Tradeshows? Cold calling?
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getting in front of customers?
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they’re looking for your capabilities. Our Buyers aren’t casually
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Fabricating.com, you don’t compete with low-cost, overseas
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www.fabricating.com Custom Parts. Custom Made in the U.S.A.
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Right U.S. Supplier: SPARkS Fly
moldmakingtechnology.com 61
Precision Laser TechnologyPLT
[email protected] www.PrecisionLaserTech.comTEL 585.458.6208 FAX 585.458.6209
Laser Engraving and Welding Servicesfor Complex Molds
MoldMaking Marketplace
work in progress
Join an engineering or sales team as we continue to grow,
setting new standards and supporting our customers.
To discuss, contact Glenn Starkey at [email protected].
Linkedin.com/in/gLennstarkeypcic | pcic-group.com
Roehr is expanding its engineering/technical support team.
If you’re interested in joining a company that’s having an
industrywide impact, contact Keith Laporte at 978-562-4488.
www.roehrtool.com/careers
Product Focus / K Show October 16-23, 2013, Dusseldorf, Germany
Remote Monitoring SystemAt K 2013 in Hall 01, Booth E36, AST Technology—a PCIC Group Company specializing in comprehensive
support services to assist OEMs with optimizing costs, quality and delivery of injection mold building
and plastic part production—will preview an upgraded version of the CVe Monitor that also incorporates
the new CVe Live™, a system giving users the ability to view mold activity in real time.
Using a website interface, the CVe Monitor enables tool owners to view information such as cycle
times, quantity of cycles, and maintenance for tools running around the globe. CVe Live allows users
to see alerts if maintenance is due or overdue, while also generating graphs and reports on the
activity of a specific or group of tools, including a comparison via the Program Watch module. This
provides supply chain/logistics personnel with up-to-the-minute information on the inventory levels
in the supply chain.
For more information from AST Technology GmbH of 32051 Herford, phone
49 5221 7 630 695 or visit ast-tech.de
www.imscompany.com
Phone:1-800-537-5375
• Guide and Parting Line Components
•Wear Plates/Strips, Bushings, Pins and Clamps
... and MUCH MORE!
62 MoldMaking Technology October 2013
REPORTEnd Market By Bill Wood
FOR mORE inFORmaTiOn:
Bill Wood, MoldMaking Technology’s Economics Editor / Mountaintop Economics & Research, Inc.
(413) 772-6436 / [email protected] / plasticseconomics.com
Output of Medical Equipment and Supplies Remains Robust
Domestic Production of Consumer Goods Holding Steady
quite favorable for the foreseeable future. These include: a growing population,
an aging population, and increased access to medical care for low income
and uninsured Americans due to the Affordable Care Act. Exports of medical
equipment and supplies will also continue to grow as access to these products
increases in many of the world’s less-developed countries.
mode, and this has pushed home prices steadily higher. This will result in higher
consumer confidence levels, and it will also encourage banks to be less stingy
with financing. All of these factors contribute to increased final demand in the
economy, and the consumer goods sector will be among the first to benefit from
the increase in spending activity.
Medical and Consumer Products
Dat
a so
urce
: Fed
eral
Res
erve
Boa
rd
Fore
cast
: Mou
ntai
ntop
Eco
nom
ics
& R
esea
rch,
Inc
.
12
10
8
6
4
2
0
-2
-42
00
1
20
02
20
03
20
04
20
05
20
06
20
07
20
08
20
09
20
10
20
11
20
12
20
13
12 M
on
th M
ov
ing
Avg
.
Medical Equipment - U.S. Industrial Production
12-Month Growth Rate (Percent)
For the year to date, total U.S. production of medical equipment and supplies is
up 8 percent when compared with the same period in 2012. This rate of growth
will gradually decelerate for the remainder of 2013, but the annual growth this
year will still be a healthy 6 percent. By the end of this year, the actual total
output of these products will be 20 percent higher than it was in 2007.
This is one of the few U.S. industries that can claim such robust growth over
the past five years. The Great Recession hit most U.S. industries hard, and many
of them have yet to climb back to their pre-recession levels. A good example of
this that hits close to home is the output of the U.S. plastics products industry.
Manufacturers of plastics products have registered solid growth in their pro-
duction levels during the past two years, but their overall output levels are still
8 percent below where they were in 2007.
The rate of change chart for the medical equipment and supplies industry
illustrates that this sector is clearly cyclical, but it does not conform to the
typical U.S. business cycle. If the cyclical pattern holds true to form, it indicates
that the rate of growth will decelerate through 2014 and will turn back up in
2015. It is too early to predict just how low the rate of change chart will dip
next year, but it is highly unlikely that this industry will contract. The long-term
demographic fundamentals that drive demand for medical products will remain
We have lowered our forecast for the U.S. production of consumer goods
(excluding high tech, motor vehicles and energy products). Earlier this year
we thought that the total output of these goods would expand by 2 percent
because we expected that the overall U.S. economy would grow by 2 percent.
We still believe it will grow by 2 percent or more this year, but the growth in
production of consumer goods will be only 1 percent. But fear not, we expect
the growth rate to accelerate in 2014.
Sluggish income growth is the reason that U.S. consumers are not increasing
their rate of spending. Households have paid down their credit card debt, and a
substantial number have been able to refinance home mortgages at rates that
are very near historical lows. However, they have not raised their spending activ-
ity, which has been felt by all segments of the manufacturing sector.
Fortunately, the economic fundamentals that favor increased consumer
spending are finally starting to emerge. The labor market is steadily healing, as
indicated by an accelerating uptrend in the U.S. employment data. Household
income levels are closely related to the trend in the job data, and both of these
indicators are starting to rise at a faster rate. The trend in home prices is
another important indicator of Americans’ willingness to spend.
The residential housing and construction sectors are well into recovery Dat
a so
urce
: Fed
eral
Res
erve
Boa
rd
Fore
cast
: Mou
ntai
ntop
Eco
nom
ics
& R
esea
rch,
Inc
.
4
2
0
-2
-4
-6
-8
-10
20
01
20
02
20
03
20
04
20
05
20
06
20
07
20
08
20
09
20
10
20
11
20
12
20
13
12 M
on
th M
ov
ing
Avg
.
Consumer Products - U.S. Industrial Production
12-Month Growth Rate (Percent)
Ad Index
moldmakingtechnology.com 63
Alba Enterprises Inc. . . . . . . . . . . . . . . . . . . . . . . . 56
Bales Mold Service Inc. . . . . . . . . . . . . . . . . . . . . . 56
Better Molding Solutions . . . . . . . . . . . . . . . . . . . . 61
Bohler-Uddeholm . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Chevalier Machinery Inc. . . . . . . . . . . . . . . . . . . . . 20
CUMSA (Comercial de Utiles y Moldes, S.A.). . . . 33
Delcam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
DME Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Edro Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Ellwood Specialty Steel . . . . . . . . . . . . . . . . . . . . . 23
Expert Technical Training . . . . . . . . . . . . . . . . . . . . 61
Fabricating.com . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Finkl & Sons Co., A. . . . . . . . . . . . . . . . . . . . . . . . . . 42
Haas Automation, Inc. . . . . . . . . . . . . . . . . . . . . . . . 11
Haimer USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Hasco America, Inc. . . . . . . . . . . . . . . . . . . . . . . . . 58
Hurco Companies, Inc. . . . . . . . . . . . . . . . . . . . . . . . . 1
Hyundai WIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
IMS Industrial Molding Supplies . . . . . . . . . . . . . . . 61
Incoe Corporation . . . . . . . . . . . . . . . . . . . . . . . . . 49
Ingersoll Cutting Tool Co. . . . . . . . . . . . . . . . . . . . . 13
Iscar Metals, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
J.W. Winco, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Mastip, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Mold Base Industries, Inc. . . . . . . . . . . . . . . . . . . . . 2
NSK America Corp. . . . . . . . . . . . . . . . . . . . . . . . . . 24
Omni Mold Sytems . . . . . . . . . . . . . . . . . . . . .Cover 3
ORYCON Hot Runner Systems . . . . . . . . . . . . . . . . 52
PCS Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8, 9
Phoenix Laser Solutions . . . . . . . . . . . . . . . . . . . . 53
Plaspec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Plastic Engineering & Technical Services, Inc. . . . 29
Precision Laser Technology . . . . . . . . . . . . . . . . . . 61
Progressive Components . . . . . . . . . . . . Cover 2, 61
Sandvik Coromant . . . . . . . . . . . . . . . . . . . . .Cover 4
Schmolz + Bickenbach USA, Inc. . . . . . . . . . . . . . . 31
Sescoi USA, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Single Source Technologies . . . . . . . . . . . . . . . . . 28
Sodick Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Sumitomo Electric Carbide Inc. . . . . . . . . . . . . . . . 15
System 3R USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
TechSpex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Tool Alliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
U.S. Union Tool, Inc. . . . . . . . . . . . . . . . . . . . . . . . . 39
WALTER USA, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Yama Seiki USA, Inc. . . . . . . . . . . . . . . . . . . . . . . . . 43
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Tooling Solutions
tip
64 MoldMaking Technology October 2013
How to Optimize Moldmaking Milling Operations
Cutting tOOls
By Troy Stashi
The lead angle of your cutter has a dramatic effect on not
only the chip that you generate, but also the cutting forces in
both the axial and the radial directions. All of this can affect
your overall productivity. There are many milling lead angle
concepts on the market today and each is designed to per-
form a specific task.
A square shoulder cutter produces the majority of its cutting
forces in the radial direction, making this design best suited
for not only a square shoulder, but machining components
where vibration could be an issue.
With the square shoulder cutter, you get no chip-thinning
effect. The programmed feed rate per tooth is exactly equal to
the actual chip thick-
ness. This makes a
square shoulder mill-
ing cutter a smart
choice for compo-
nents with thin sur-
faces, in cases where
you have unstable
fixturing; machines
having weaker spin-
dles; and, of course,
when you need to
produce a 90-degree
shoulder.
Of note, the 90-
degree lead angle is
commonly used in face milling. It can easily perform the task,
but it’s not commonly the most productive or cost-effective
choice. A cutter with a 45-degree lead angle should be your
first choice for face milling.
An important rule to remember is that as the lead angle of
your cutter decreases, so does the chip thickness. Due to this,
you have the opportunity to increase your feed rate to com-
pensate. This makes the 45-degree lead angle cutter a smart
choice for general-purpose face milling operations, reducing
vibration on long overhangs and machining short chipping
materials—such as grey cast iron.
Today, many companies are using a strategy employing
light cutting depths at very high feed rates. Using a very small
lead angle—such as 10 degrees—should be your first choice in
machining with low depths of cut.
As we mentioned, with a square shoulder, you get no chip-
thinning effect. However, as the lead angle decreases, the chip
thins. As we decrease the chip angle all the way from square
to 10 degrees, the chip is thinned out to almost nothing.
Here, you can increase your table feed and achieve the
proper chip thickness. Milling cutters that have a very small
lead angle are a smart choice for high feed machining with
low cutting depths, applications with long and weak setups
and effective hole making using all three axes.
FOr MOre inFOrMatiOn:
Sandvik Coromant / (800) 726-3845 / sandvik.coromant.com
Imag
es c
ourt
esy
of S
andv
ik C
orom
ant.
Video
Access video
at end of article.
VideO: Face Milling http://short.moldmakingtechnology.com/ facemill
COnTriBuTOr
Troy Stashi is Industry & Application Specialist - Automotive/Milling for Sandvik Coromant.
There are many milling lead angle concepts on the market today
and each is designed to perform a specifc task.
Face milling.
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