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april 2013
Volume 16 / Number 4
DesigN / bu ilD / repair
Essential Cutting
Strategies for
Mold Machining PG 26.
FEATURES
Pairing GD&T with
Industrial CT Scanning PG 30.
Energy Savings in Multi-
Cavity Molds PG 33.
CASE STUDY
Collapsible Cores Compress
Design and Machining
Time PG 17.
ViDeo
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M A C H I N I N G C E N T E R S T U R 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 S U P E R I O R C O N T R O L S
achinists
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ow Hurco
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PublisherClaude J. Mas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cmas@gardnerweb.com
Metalworking Group PublisherTravis J Egan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . tegan@gardnerweb.com
Editorial DirectorChristina M. Fuges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cfuges@gardnerweb.com
Senior WriterSherry L. Baranek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . sbaranek@gardnerweb.com
Economics EditorBill Wood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .billwood@plasticseconomics.com
Contributing Writer, Special Projects Jan Bottiglieri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 847-923-5729 / janbottig@aol.com
Art DirectorCarla M. Turner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cturner@gardnerweb.com
Advertising Production ManagerBecky Helton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bhelton@gardnerweb.com
MoldMaking Technology magazine (ISSN #1098-3198) is published monthly by Gardner Business Media, Inc., 6915 Valley Avenue, Cincinnati, Ohio 45244. 800-950-8020, 513-527-8800, Fax: 513-527-8801, gardnerweb.com. Canadian Agreement #40012278.Nonqualifed subscription rates per year are $89.00 in the United States, $99.00 in Canada and
Mexico. All other countries are $200.00 per year, payable in U.S. funds. Single copies $10.00 per issue in the United States and Canada. CANAdA POST: Canada Returns to be sent to Bleuchip International, P.O. Box 25542, London, ON
N6C 6B2. Publications Mail Agreement #40612608. POSTMASTER: Send address changes to: MoldMaking Technology magazine, Gardner Business
Media, Inc., 6915 Valley Avenue, Cincinnati, Ohio 45244.Entire contents copyright 2013. No portion of this publication may be reproduced in any form
without written permission from the publisher.Views expressed by the bylined contributors should not be construed as a reflection of the opinion
of this publication. Publication of product/service information should not be deemed as a recommen-dation by the publisher. Editorial contributions are accepted from the moldmaking industry. Contact the editor for details. Product/service information should be submitted in accordance with guidelines available from the editor.Change of address: Send old label as well as new address to Circulation, MoldMaking Technology
magazine, Gardner Business Media, Inc., 6915 Valley Avenue, Cincinnati, Ohio 45244.Periodicals postage at Cincinnati, Ohio and at additional mailing offices.
PRINTED IN THE U.S.A.
2 MoldMaking Technology April 2013
6915 Valley Avenue Cincinnati OH 45244-3029P 513-527-8800Fax 513-527-8801 gardnerweb.com moldmakingtechnology.com
Richard G. Kline, CBC | President
Melissa Kline Skavlem | COO
Richard G. Kline, Jr. | Group Publisher
Tom Beard | Senior V.P., Content
Steve Kline, Jr. | Director of Market Intelligence
Ernest C. Brubaker | Treasurer
William Caldwell | Advertising Manager
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 | Senior Event Manager
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Great Tips from This Issue5TRICKS OF THE TRADE
Contents
4 MoldMaking Technology April 2013
Features
26 Cutting Tools Essential Cutting Strategies for Mold Machining: Without the right application techniques, even the best tools can fall short of their potential.
30 Inspection/MeasurementPairing GD&T with Industrial CT Scanning: Industrial CT scanning has become an integral part in GD&T and how the internal measurement of complex component parts should be facilitated.
33 Hot RunnersEnergy Savings in Multi-Cavity Molds: Simplifying maintenance and energy savings in the development of hot runner systems.
38 Mold Maintenance/RepairIn the Trenches: Out of the Mouths of Babes: How do you know when youre just fighting fires, performing controlled firefighting or completing true corrective action.
40 Software Circuiting Done Right: Using cooling simulation to circuit your cooling lines properly.
44 Mold ComponentsThink Metric: Its All in the Numbers, Part 2: Feedback from the field on making the metric conversion in your shop.
Departments
6 From the Editor: Where Is Your Top 10 T-shirt?
6 Whats New on MMT Online: Cutting Tools
8 New Business Opportunities: Automation
10 Your Business: Detailed Training Plan
12 Moldmaking Business Index
14 Profile: Association for Advancing Automation (A3)
17 Case Study: Components
20 Case Study: Inspection/Measurement
48 Product Focus
53 MoldMaking Marketplace
54 End Market Report: Aerospace and Packaging
55 Ad Index
56 TIP: Supply Chain Management
ON ThE COvER
Image courtesy of Sandvik Coromant (Fair Lawn, NJ). The CoroMill300 performing helical milling where the cutter is being
helically ramped into the material on a specific angle to a certain
depth. The cutter then machines the entire surface at that level
before repeating. This family of light cutting face and profile
milling cutters has a positive round insert concept designed to
handle a range of operations common to moldmaking.
1. Roll Up Your Sleeves Roll-in and constant engagement techniques by programmed radius move-ments of the cutter create thin chips on exit that maximize productivity.Page 26.
2. Wining Formula Jobs-to-be-done plus GD&T plus industrial CT equals successful internal complex geometry inspection.Page 30.
Energy Boost Keep in mind that en-ergy savings is not limited solely to the system itself (thanks to reduced ther-mal dissipation between system and hot half), but also to reducing scrap during system restart. Page 33.
4. Go With the Flow After determining the best cooling line locations and approximate cooling time, the analyst turns his attention to the coolant fow. Page 40.
5. Metric Moves Being a metric shop will open up opportunities in Europe. The effciency improvements in design will also begin to pay dividends. Page 44.
Apirl 2013 Volume 16 / Number 4
562017
vIDEO ACCESS
Images courtesy of (left to right) Roehr Tool, Mitutoyo and Rexam.
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This MonTh on moldmakingtechnology.com
From the Editor
6 MoldMaking Technology April 2013
MMT Zone: Cutting Toolsmoldmakingtechnology.com/zones/cutting-toolsCutting tools are used on machine tools to cut metal, and are one component of the overall mold machining process to consider when looking to improve speeds, feeds, wear and surface finish. Technologies include end mills, drills, inserts, spindles, toolholders, fluids and coatings. There are many styles, substrates and coatings to consider during selection.
Browse Past Cutting Tools Articles by Type: Features, Case Studies and Tips Tips for Successful Hard Milling of Complex Molds:
Emuge shares that when mold and die applications demand hard milling of materials up to 66 HRC, using the right end mills, cutting parameters and machining methods is critical for success.
Taking Advantage of Carbide Material for Your Mold Designs: U.S. Union Tool presents the development of an end mill that can cut 3D features into a carbide material demonstrates how mold manufacturers can reap the benefits of carbide material for their mold designs without a time or cost penalty.
Tooling Up for Mold Machining: Seco Tools reviews the following considerationsmachine tool capability, intended milling techniques, programming, workholding and toolholdingwhich are key for your cutting tool selection process.
Button Cutters Reinvented: Millstar explains how button cutters still offer a competitive edge in many manufacturing processes, despite claims they are being phased out.
Search Cutting Tools Products Cutting Tools Catalog, Tool Alliance Insert Geometries/Customized Toolholders,
Sandvik Coromant End Mill Holder System, Techniks Rotary/Cutting Tools Catalog, Walter USA Extended Length Toolholders, RegoFix
Find a Cutting Tools Supplier via the Following Categories: Coolants Cutting Fluids Cutting Tools End Mills Grinding Wheels High-Speed Electric
Spindles
Browse Cutting Tool Videosmoldmakingtechnology.com/videos/browse/cutting-tools Tips for Successful Hard Milling of Complex Molds Cutting Carbide with an End Mill Improving Milling Accuracy
The past year has shown me that our Top 10 Reasons to
Be a Moldmaker t-shirts have become a little infamous
from shops calling wanting to purchase a bundle for
their team to instructors looking to present them as part
of a reward package honoring their top students to guys
sending me photos showing where the t-shirts have
been how about a family cruise vacation!
I know I enjoy exposing the lighter side of the guys
and gals who work so hard to keep this industry going,
so Im thrilled when I feel it from you too. And so, it is
that time of year again. Time to ask you to submit a Top 10 reason to be a mold-
maker and lets try to top last years list! Im sure you wont disappoint.
Visit: moldmakingtechnology.com/top10/register.cfm to submit your name
and Top 10 reason.
All participants will receive a free exhibit
hall pass to amerimold ($25 value) and the
shirt! Authors of submissions selected for the
Top 10 will receive a free amerimold ALL
ACCESS PASS, which includes: a free exhibit
hall pass ($25 value), a Technical Conference
Pass ($295 value), a ticket to the amerimold
VIP Networking Reception ($50 value),
and your name, title and company name
will be listed in the amerimold 2013 Event
Directory! The author of the #1 Reason to Be
a MoldMaker will receive the amerimold ALL
ACCESS PASS AND a $250 Visa gift card!
This t-shirt has been a tradition of MoldMaking Technology magazine since the
early days of the MoldMaking Expo back in the nineties. Each year these shirts
put the industrys humor to the test and showcase the lighter side of moldmaking.
The final 10 are revealed at our annual trade eventamerimold expo, which is
taking place this year on June 12 & 13 in Rosemont, IL. And we will be distribut-
ing the 2013 custom-printed t-shirts to amerimold attendees who stop by the
MoldMaking Technology booth and complete a simple industry survey.
Now while were discussing reasons, let me give you a few for making sure
you attend amerimold this yearoutside of grabbing your Top 10 tee: our
annual party night; networking opportunities with peers and customers; a
technical conference broken down into Engineer, Build and Maintain blocks;
show floor technology presentations; and, an exhibit hall full of technology
solutions specific to your needs, just to name a few.
So, What Are Your Top 10 Reasons to be a Moldmaker? We want to know
at least your number one reason. The funnier the better, so dont hold back!
Where Is Your Top 10 T-shirt?To get your own, enter your top reason to be a moldmaker.
Christina M. Fuges
Editorial Director
Inserts Lathe Tooling and Accessories Profilers Reamers Tool Management Systems Toolchangers Toolholders
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8 MoldMaking Technology April 2013
New Business Opportunities
Moldmaker/Molder Doubles Down
With Technology Investment
By Sherry L. Baranek
Micro Mold Co., Inc. and Plastikos Inc.sister companies
that are based in Erie, PAhave committed to investing 1$
million in capital expenditures this year, which will further
increase moldmaking capacity and cleanroom molding and
further solidify its niche as a medical moldmaker/molder.
The Micro Mold facility is investing in new equipment in
automation and robotics, which Micro Mold General Manager
Ryan Katen points out will enable the company to provide
more 3D EDM work, lights-out operations and overall effi-
ciency, quality and capability expansions. We already have a
very large investment in technology, Katen says. Were con-
sidering the current infusion of capital as doubling down on
our mold shop. At a time when many others are exiting the
domestic toolmaking business
because of its low margins
and ever-growing require-
ments for capital investments,
we see it as a critical compo-
nent to the ultimate success
of our customers end product
in the market. These invest-
ments in automation allow
us to provide high quality,
while remaining price com-
petitive, so that an overseas
option is less and less attrac-
tive to our customers.
Micro Mold currently has
one automation cell and is
now working to build the
second. We added another
machining centera high-
speed Mori Seiki CNCand are tying that into a System 3R
robot to alleviate the bottleneck in the EDM department
and thus further reduce our leadtimes, Katen explains. We
are quoting a lot of multiple tool packages and much of that
work requires these types of machines.
The company recently added a cleanroom to focus on its
medical customer base at its Plastikos facility, and the result-
ing medical business is approaching an all-time high, notes
Micro Molds. Our existing medical customers have grown
and we are in the works of building up some other medical
accounts while looking to acquire some new ones, Katen
emphasizes. We are running out of capacity so hence the
expansion. We want to provide even better serviceand qual-
Phot
o co
urte
sy o
f M
icro
Mol
d Co
. Inc
.
For More inForMation:
Micro Mold Co., Inc. / (814) 838-3404 / micromolderie.com
Plastikos Inc. / (814) 868-1656 / plastikoserie.com
At a time when many
others are exiting the
domestic toolmaking
business because of its
low margins and ever-
growing requirements
for capital investments,
we see it as a critical
component to the
ultimate success of our
customers end product
in the market.
Micro Mold employee Steve Shultz in front of the companys CNC EDM cell.
Plans are underway to add a second cell.
ityfor existing and potential customers.
The addition of an 88-ton Arburg cleanroom molding press
effectively increases the companys molding capacity by 50
percent, Katen notes, and brings the total number of presses
to three. This allows us to meet the rising demand in this
market while giving us the ability to offer Class 10,000 (ISO
7) cleanroom moldinga rare capability amongst contract
molders, he comments.
Katen adds this is a short-term expansion. We are looking
at some other options for a longer term expansion to further
increase our capacities, but for right now this third press
gets us to the next stepping stonegrowing organically and
not trying to do too much, but keeping up with the demand
we are seeing.
Katen is confident that these investments will pay off in the
long-term and result in the companys continued success.
We are just making sure that we are current with equipment
and technology that we need to continue to support the med-
ical industry and its demanding leadtimes.
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Your Business
10 MoldMaking Technology April 2013
machine set-ups. What do they need to know before they can
do it? They need to know at least the following (and a lot more):
how to indicate a part straight; proper workholding; how to
identify the axes of a machine, etc.
When a person starts sweeping the floors, they should be
told that they need to know the above items before they will
get an opportunity to advance to machine set-ups. They should
be presented with their options for how the company will help
them learn those items and how they will be measured. When
we develop people before they actually need the skill, they know
they are being trained and they will be able to more easily see
the path ahead of them.
By being able to see the path in front of them through a
robust training plan, employee retention will increase dramati-
cally. Each job description in your company should have a
detailed training plan in place. This will help your employees
see their future in the trade. Our skilled tradesmen and women
are, and will continue to be, who define us as an industry. We
must invest as much effort and planning into how we will
handle them as we do in creating a plastic mold.
By Ryan Pohl
When it comes to the skilled trades, the words training and
retaining are undoubtedly connected. When a company
invests in training for their employees, retention is always
higher. Yet the definition of training can be confusing. In this
industry, people are going to learn no matter what. Whether
they are learning to be a moldmaker, a CNC machinist or a
designerthey are going to learn by simply being part of the
trade. Though there is a lot of learning taking place, often-
times a structured path of training is missing, leaving the
worker confused and sometimes disgruntled wondering if
they have a future.
Learning and training are not the same thing. We can
learn a lot about a topic, but that does not mean we are well
trained. By definition training is structured; it has a start
point and an end point. Training is measurable. Though
learning should never end, we should know when training
is complete. We should know when we are being trained
and when we are not. Most
people can tell the differ-
encethis is why training
is connected with retention.
Employees can tell the dif-
ference between a company
that expects them to learn
as they go and one that has
taken the time to make sure
they are being trained prop-
erly. Employees can recognize whether or not they are being
presented a path of development or a path to nowhere.
This is one of the single biggest ways that companies lose
their employees. They fail to present a clear career path for
their employees. They allow their most valuable asset to be
developed through tribal-knowledge alone. Many of our new-
est workers in the industry are lost because of it. To retain
your next generation of talented workers, you must offer a
clear path of development that is hinged on structured and
measureable training.
This means you must define each job description and map
out the path to get to the next logical job (or jobs) up the lad-
der. The map should include a detailed list of the necessary
competencies needed to progress. For example: if a person
starts in your shop sweeping floors, where would they go after
that? And what would they need to know to get there? It seems
a logical next step from sweeping floors might be to do CNC
contRiButoR
Ryan Pohl is President of Expert Technical Training, LLC.
For more inFormation:
Expert technical training, LLc / (616) 785-5733
ryan.pohl@expert-technical.com / expert-technical.com
By being able to see the
path in front of them
through a robust training
plan, employee retention
will increase dramatically.
Finding, training & retaining employees
Part 3 of a Series Detailed training Plan
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MoldMaking Business Index
12 MoldMaking Technology April 2013
Received sub-index for January is 52.9. The
sub-index for Materials Prices spiked up
this month to 73.9. Supplier Delivery Times
are getting longer, and this component
escalated to 53.3 in February. Offshore
orders extended their downward trend last
month, but the pace of decline slowed in
recent weeks. The Exports sub-index is 47.7.
The MoldMaking Business Index is
based on a monthly survey of subscrib-
ers to MoldMaking Technology magazine.
Using the data from this survey, Gardner
Research calculates a diffusion index
based on 50.0. A value above 50.0 for the
index indicates that business activity
expanded when compared with the previ-
ous month, and a value below 50.0 means
that business levels declined.
Total Index for February 2013: 51.3
Rebounding from a three-month downtrend, our survey of
the North American moldmaking industry indicates that
overall activity levels increased in February. The MoldMaking
Business Index for February 2013 is 51.3 (a value greater than
50.0 indicates an increase in business levels for the month).
The latest index value is a 1.5-point increase from the January
value of 49.8, but it is a 7.2-point decrease from the 58.5 regis-
tered in February 2012.
A rise was reported in the crucial New Orders category for
the second straight month, and the Production category also
registered a second consecutive increase. Supply conditions,
as measured by the Supplier Delivery Times and Materials Prices
components, were again the most notable negative factors
in the index this month. Supplier delivery times continue to
get longer, and materials prices have increased for 15 months.
Prices Received remained steady-to-firmer, though the trend
in prices received is not keeping pace with the gains in costs
for materials. Future Expectations were substantially more
optimistic.
The New Orders component posted an encouraging 53.7
in the latest month. The gains in orders so far this year are
notable given all of the uncertainty generated by the poli-
cymakers in Washington in recent weeks. This gain in new
orders meant that the recent slide in Backlogs continued
to decelerate. The Backlog sub-index is 46.3 for February.
The Production sub-index of 54.1 continued to gain momen-
tum from the previous month. The Employment component
is 52.9, which means that payrolls were higher this month.
The prices received in the moldmaking sector gradu-
ally strengthened for the second straight month. The Prices
The growth rate in the U.S. economy has gradually improved through the frst two
months of this year, and this is corroborated by the recent trend in our MoldMak-
ing Business Index. The underlying fundamentals of the U.S. economy continue
to strengthen. The residential construction and real estate sectors are entering
a full-recovery mode, and this is pushing up house prices and household wealth.
The stock market recently hit an all-time high, and this too is generating more
household wealth. The Federal Reserve Board is keeping interest rates extremely
low, thus providing an incentive for companies and investors to take more risk.
Low interest rates combined with rising wealth in the consumer sector and solid
proft levels in the business sector are the ingredients required for a surge in
the employment data. All that is missing is confdence. The recent sequestration
debacle in Washington has dampened enthusiasm in recent weeks, but the nega-
tive effects of this should wear off by the second half of this year. Therefore, we
expect economic activity to chug along at the current rate of growth for another
quarter or two, and then accelerate at the end of this year and through 2014.
Sub-Indices January December Change Direction Rate Trend
New Orders 53.7 54.9 -1.2 Growing Slower 2
Production 54.1 52.1 2 Growing Faster 2
Backlog 46.3 43.8 2.5 Contracting Slower 11
Employment 52.9 51 1.9 Growing Faster 2
Exports 47.7 45.1 2.6 Contracting Slower 9
Supplier Deliveries 53.3 52.1 1.2 Lengthening More 3
Material Prices 73.9 67.4 6.5 Increasing More 15
Prices Received 52.9 51.7 1.2 Increasing More 2
Future Business Expectations 69.2 65.7 3.5 Improving More 15
MoldMaking Business Index 51.3 49.8 1.5 Growing From Contracting 1
55
50
45
40
60
1/13
12/12
11/12
10/12
9/12
8/12
7/12
6/12
5/12
4/12
3/12
2/12
1/12
12/11
2/13
MoldMaking Business Index
-
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14 MoldMaking Technology April 2013
Profle
The Association for Advancing
Automation: The Voice of Automation
By Sherry L. Baranek
The Association for Advancing Automation
(A3; Ann Arbor, MI) is a global, not-for-profit
organization for three trade associations
Robotic Industries Association (RIA), AIA
Advancing Vision + Imaging and Motion
Control Association (MCA)that pledges
to be the global advocate for the benefits of
automation in every market space.
According to the A3 Director of
Communications Bob Doyle, the rebranding
of the three associations under the name
A3 is a relatively new strategy. We are dedi-
cated to serving the members of RIA, AIA
and MCA, Doyle states. We sponsor trade
shows, conferences and other networking
events, develop some of the worlds leading
websites on automation technologies, col-
lect industry statistics and generate market
research, develop consensus standards,
provide multiple certification programs and
engage in a wide variety of other education-
al activities. We interact on a regular basis
with people from our more than 650 member organizations
around the world, and are always coming up with new ways
to serve them better.
Of these 650 members, Doyle notes close to 100 of them
are international. Since many automation technologies
are introduced overseas first, we intend to keep our eye on
automation developments all over the world, he notes
While A3 serves as the voice for the need to automate, the
RIA, AIA and MCA will continue to focus on how companies
Attendees gather at Automate 2013a biennial trade show showcasing
the latest in automation technologies.
and organizations specifically can apply robots, vision and
motion control, Doyle notes. Our developing strategy is to
engage stakeholders from around the world and demonstrate
why automation technologies and ideas transform the way
business is done todayand into the future, Doyle notes. To
accomplish this goal, A3s services include the following:
Host business events and networking opportunities;
Media outreach, including placement of opinion
pieces and articles;
Collaborate with other related industries and associations;
Connect with governmental organizations and
nongovernmental organizations (NGOs);
Reach out to international partners to expand its global
network; and
Educate the public on why automation is good.
One of the A3s most important networking events is its bien-
nial trade showAutomate 2013 (automate2013.com), held last
January in Chicago. The A3 also holds a show specifically for the
vision and imaging industries (The Vision Show; visiononline.
The A3 Umbrella
The Robotic Industries Association improves the regional, national and global
competitiveness of the North American manufacturing and service sectors
through promotion and enhancement of robotics and related automation.
The AIA - Advancing Vision + Imaging advances the understanding and use
of vision and imaging technologies to drive global expansion and growth.
The Motion Control Association promotes understanding and use of motion
control technologies and developing business opportunities.
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16 MoldMaking Technology April 2013
Tool HoldersShrinking TechnologyBalancing MachinesMeasuring InstrumentsTool Management
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:
The patented safety belt
for your cutting tools.
The new standard for roughing applications
For more inFormation:
A3 / (734) 994-6088
bdoyle@a3automate.org
a3automate.org
Robotic Industries Association
robotics.org
Advancing Vision + Imaging
visiononline.org
Motion Control Association
motioncontrolonline.org
org; slated next for April 15-17, 2014) on alternating years.
According to Doyle, the companys biggest challenge is to
be the voice of automation and educate potential users about
the benefits of automatingespecially small- to medium-size
companies who may feel automation is out of their realm. We
want to publish white papers and create video testimonials
on our website that share success stories on companies who
have successfully automated and are now reaping the benefits,
Doyle notes. And, while the organization doesnt have any
moldmaker/molder members yet, it is Doyles hope that the
industry reaches out to A3 for assistance in automation solu-
tions to improve the mold manufacturing process.
Additionally, the automation industrymuch like the
moldmaking industryfaces a skilled labor gap. Recently
there was a segment on 60 Minutes that suggested robots are
taking the place of peoples jobs, Doyle states. Our view is
that this is completely wrong and not looking at the bigger
picture. Automation systems create jobs and make companies
more competitive and able to make higher quality products.
This in turn creates jobs that are more technical in nature
and higher paying. In actuality a lot of these companies are
struggling to find people to fill these positions. A lot of our
members cant find people to fill these jobs. The real focus
should be on education at the vocational
education, community college and univer-
sity level to fill these job shortages.
Doyle has a number of short- and long-
term plans for the A3, including expand-
ing the website, extending its global
reach through networking with current
members to develop such contactspar-
ticularly with companies in Europe, Asia,
South America and Mexico, and making
the manufacturing technician (some-
one able to program and run higher tech
equipment) the next skilled trade, like a
plumber or electrician is today.
Phot
os c
our
tesy
of
the
A3.
A robot demo at Automate 2013.
-
Case Study / Components
moldmakingtechnology.com 17
F&M Tool and Die Co., Inc. (Leominster, MA)a full service
mold manufacturer from prototype to production for a
number of industrieswas asked by one of its customers to
build two multi-cavity molds for a couple of large industrial
parts. The parts were similar but different enough to warrant
two individual molds. The two large, thick-walled parts
had deep undercuts requiring massive side actions and inter-
nal threads that needed to be relieved. Each mold would
weigh approximately 10,000 pounds.
According to F&M Tool and Die President/Owner Michael
Gasbarro, the customers proprietary product line consists
of mostly large, complex parts with slides and unscrewing
mechanisms being the typical approach for the mold con-
structions. The unscrewing mechanisms add to the complex-
ity of both the mold design and build, he emphasizes.
Gasbarro, having built several collapsible core molds in the
past using both RT Series
and Dovetail style (DT)
cores from collapsible core
manufacturer Roehr Tool
(Hudson, MA), approached
his customer with the
thought of replacing the
unscrewing mechanisms in
these two new molds with
DT Cores.
DT Cores are positive,
mechanically actuated col-
lapsible cores that elimi-
nate complex gear and
rack approachesresult-
ing in a simpler mold and
a faster cycle time, notes Roehr Tool Engineering Manager
David Helenius. Additionally, the DT Cores compact design
allows for shorter stack height, tighter cavity spacing, and
also creates opportunities for use in slides or on the station-
ary side of the mold.
F&Ms customer listened to Gasbarro as he explained what
he has found to be the benefits of collapsible cores and the cus-
tomer discovered that they could build one of the tools with the
new to them collapsible core product. The other tool would
have to be built with their traditional methods since the collaps-
ible cores were not suited for that tool without making changes
to their part. Nevertheless the two projects turned out to be a
great side-by-side, simultaneous case study comparing collapsible
cores to traditional unscrewing mechanisms.
Multiple Benefits
It wasnt long before the benefits of Roehrs cores started to
surface, notes Mark Girard, Chief Engineer at F&M Tool. This
customers molds are always a challenge to designcombining
large side actions with unscrewing mechanisms in a multi-
cavity mold, he states. So for the first tool, I started my typi-
cal mold design process, while at the same time sending the
customers second part model to Roehr Tool for the design and
engineering of the Dovetail collapsible cores.
What F&M Tool received
back from Roehr Tool was
much more than the mold
manufacturer expected.
Roehrs engineers designed
the complete DT Core
assembly and provided
conceptual drawings of the
mold base from the parting
line back.
While the project required extra-long DT cores to mold the internal
threads of the large parts, F&M was able to eliminate the need for complex
unscrewing mechanisms resulting in a simpler mold construction and a
reduction in overall mold size.
Speed to MarketCollapsing Cores
Compress Design and
Machining Time
-
18 MoldMaking Technology April 2013
Case Study / Components
Compressed Mold Design Time
What F&M Tool received back from Roehr Tool was much
more than the mold manufacturer expected. Roehrs engi-
neers actually designed the complete DT Core assembly
and provided me with conceptual drawings of the mold base
from the parting line back, Girard elaborates. These draw-
ings showed me the plate stack and thicknesses required
along with the operation and sequence required to function
the cores. After some review of the concepts and an approval
process, Roehr created a complete 3D model of the DT Core
assembly, which I was able to take and drop right into my
3D mold design. Roehrs assistance and upfront engineering
took much of the guesswork out of the second tools mold
design and saved us considerable time.
Roehr Tools Helenius expands on Girards statements.
Over the past couple of years we have added to our engineer-
ing department, and are now able to supply new and repeat
customers with a higher level of engineering and design sup-
port in relation to our products, Helenius comments. We
are also now capable of supplying some customers with com-
plete mold designs or mold retrofit designs in both 2D and
3D formats.
Reduced Machining/Assembly Time
During mold build and assembly, more benefits of using the
DT Cores became evident. Although both molds required
similar side action components, with the unscrewing mold,
multiple components including racks, gears and hydraulic
cylinders had to be manufactured, purchased
and installed, Gasbarro states. With the DT
Core mold, all of this was eliminated. The com-
plexities are integral to the collapsible cores in
a nice compact, modular assembly. The mold
base machining became a matter of a few simple
bores, pockets and tapped holes. Machining
and assembly time between the two molds was
reduced considerably.
Easier Set-up and Start-up
And the benefits did not stop there. When my
customer received both molds, the first thing
they noticed was the physical appearance
comparing the two, Gasbarro says. Without
the visual racks and hydraulics required with
the unscrewing mold, the DT Core mold looked
cleaner, more compact and was much easier
to handle. Installation into the press, set-up and start-up
times were also reduced with the collapsible core mold.
Additionally, Gasbarro notes that both molds started up and
produced excellent looking, functional parts during the initial
sampling, but a problem arose running the unscrewing tool,
when one of the molders hydraulic fittings developed a leak.
Cycle Time Reduction
Gasbarro notes that the molded parts thick wallsa cycle
time limitermeans that the above comparison did not
expose one of the major benefits of collapsible cores, which
is cycle time reduction. But, the other benefits realized right
from the startfrom engineering throughout the mold build
and into productionshould make a good case for anyone
with an undercut or threaded application to consider Roehr
Tool and their collapsible cores.
We will be the first to admit that collapsible cores are not
suited for every application and if a customer sends us a
part for review that would be a better fit with another meth-
od, we will certainly relay this opinion to the customer so that
they can make the best decision for their product, Gasbarro
concludes. However, DT Cores have secured our respect and
a place in our mold building arsenal.
For more inFormAtion:
F&M Tool and Die, Inc. / (978) 537-0290
mike@fmtoolanddie.com / fmtoolanddie.com
Roehr Tool Corp. / (978) 562-4488
david.helenius@roehrtool.com / roehrtool.com
Close-up of a custom designed and manufactured DT Core, which provided
F&Ms customer with the required long molding length and deep thread depth.
Phot
os c
our
tesy
of
Ro
ehr
Too
l.
-
20 MoldMaking Technology April 2013
Case Study / Inspection/Measurement
CMM Integral
To Growth Strategy,
Overall Capabilities
CMM operator programming a new job on a CMM.
By Dave Schwab
Yahagi America Molding, Inc. (YAMI, Park City, KY) recently
sought out new metrology technology to capture a greater
share of business from its largest customer. As a result of the
investment, the company expects to nearly triple its revenues
in the next few years because of an increased ability to process
a wider range of partsespecially with tighter tolerance work
with stringent quality control demands.
We were at a pivotal moment in company history, says
Greg Parker, Quality Supervisor with YAMI. Our larg-
est customer wanted to expand the amount of business we
handled for them. However, growth would require technology
upgrades and a mindset with some pretty big changes. Our
strategic partnership with Mitutoyo helped us to increase our
business and develop a stronger relationship with our largest
customer.
YAMI, a Tier 2 automotive supplier making injection
molded parts found throughout Japanese automobiles, turned
to Mitutoyo America Corporation (Aurora, IL) for increased
metrology capabilities found in a state-of-the-art CMM, as well
as their newer contour and surface roughness testing equip-
ment. Specifically with the new CMM from Mitutoyo, YAMI
addressed several points that were important in achieving this
growth goal:
Tighter part tolerances and the ability to measure and
document quality control requirements
Lower production costs
Molding of abrasive materials and how to handle its
detrimental effect on mold wear
Mold maintenance/repair services that can keep up with
demanding production schedules
Original Business Focus in Non-Critical
Tolerance Molding
YAMI was conceived in 2003 to serve the injection molding part
production business for Denso Corporations North American
facilities. YAMI currently produces approximately 4 million parts
monthlydouble the volume from just a few years agofor
various applications. The majority of the parts is found in less
critical tolerance HVAC component parts. Its 27 all electric injec-
tion molding machines range in size from 18 to 280 ton units.
They are fully automated with take out and gate cutting automa-
The appropriate strategy in precision measurement
equipment additions helped YAMI satisfy customer
quality and productivity levels. And the addition of
future in-house mold building/repair/engineering capa-
bilities will help serve their customer base even better.
Phot
os c
ourt
esy
of M
itut
oyo
Amer
ica
Corp
orat
ion
and
Yaha
gi A
mer
ica
Mol
ding
, Inc
.
-
CUMSA USA, LLC
950 Stephenson Hwy (Suite 106)
MI-48083 - Troy
United States
WEB: www.cumsa.com
MAIL: info@cumsausa.com
TEL.: +1 248 850 8385
FAX: +1 248 850 8385
DO YOU WANT TO REDUCE YOUR ?CYCLE TIME
Va
cuu
mje
t S
yste
m
Why we need to vacuum the cavity?
Before injecting the plastic, there is air trapped inside the
cavity. If we can remove this air, the plastic is free to fill the
whole cavity and will not find any counter-pressure slowing
down its flow.
Old problems...NEW SOLUTIONS!
DO YOU WANT TO OF YOUR PLASTIC PART?IMPROVE THE QUALITY
Application example with Vacuumjet Valve (VV) and Automatic Vacuumjet (VK)
The vacuum is produced through the valve, the ejectors and sleeves maintain it.
Application example with Vacuum Control (VM) and 3 Vacuumjet+ (VG) units.
The vacuum is produced through the ejectors and sleeves.
CUMSA has created a series of products that removes this air,
and give many benefits when molding the plastic parts. These
benefits are (among others):
- Lower injection temperature and pressure
- Reduced cycle time
- Increase in production
- Superior visual appearance (less sink marks)
- Dimensional stability (invisible weld lines)
- Uniform color
- High mechanical resistance due to perfect plastic flow
Contact us, and we will find the best solution for your mold!
-
22 MoldMaking Technology April 2013
Case Study / Inspection/Measurement
tion. A total of 150+ different production parts are produced by
YAMI. Annual sales are currently at $8 million and the company
hopes for an aggressive $20 million annual revenue goal within
the next few years.
From Outside Vendors to Inside Mold Building/Repair
Capabilities
With the new material additions came issues on how mold
engineering and repair work would be coordinated. Harder tool
steels and tool coating technologies are often required. Most
molds deliver a million shot life performance. Their heavy wear
glass-filled part molds deliver between a 600,000 to 800,000
shot life performance.
Long-term needs are continually debated. Wed love to own
our own destiny on production scheduling by adding more
internal mold repair/rework capabilities, says Parker. We
envision our facility taking over the responsibilities of ground
floor engineering/design, machining and tryout stages from
customers within the next several years.
The company is currently served by a Japanese mold building
sister company (IMEC Company, Ltd.). Up-front engineering/
build through tryout services are coordinated directly between
the customer and IMEC. They work with Midwestern mold
repair shops for any repair/rebuild needs.
Overall part inventories often need to be maintained at a
two- to three-week inventory because of the repair downtime
required with outside vendors timelines. Bringing the mold
repair work inside will help eliminate larger inventory levels.
Parker says that focusing on better communication between
customer and end supplier would lead to their eventually
bringing much of this mold design/build work to the U.S. He
believes this would have a positive effect on the number of
tryouts that typically take place today (eight to 10 attempts,
on average) versus how a localized response and direct on-site
communication could possibly lead to faster mold approval.
Future Growth in Tighter Tolerance Work
It was quite a challenge to grow toward higher precision
molding work, states Greg Parker, Quality Supervisor for
YAMI. Weve lived in the world of automotive HVAC parts in
which typical tolerances ranged from +/-.1mm to .25mm. Then
Denso started reducing their supplier base of 40-50 compa-
niesand we made the core supplier cut.
While the company could handle the production molding
capabilities, they didnt have a way to check part specifications
to tighter levels and speed of measurement. Before, their only
option was to use local services to check higher tolerance parts.
And at times, they used other limiting hand-held devices and
even a Flexbar Microscope. With larger volume work, they knew
they had to bring that work in house (typically outsourced) for
both precision and productivity.
Two key job additions include an accelerator pedal and base
assembly, as well as a Buss Acceleration Sensor (aka: BAS)
used in airbag assemblies. These parts required a much tighter
tolerance range of +/-.02 to .05mm for those parts. The BAS
part is ultrasonically welded with a metal insert, resulting in a
need for scanning 50 different points across the weld surface
to make sure it meets flatness requirements.
Parker explains that their CMM search needed to measure
quickly, accurately and cost-effectivelywith an obvious and
quick ROI payoff.
New CMM Technology Improves Production Capabilities
Their solution: a Mitutoyo Crysta-Apex CMM. They knew
that CMM technology would not only be able to measure the
tighter tolerance levels, but also handle a higher volume of
part checking.
And while most of their parts could fit in the palm of your
hand, they invested in a CMM that offers a much larger enve-
lope. They expected that future jobs might include larger
part sizes, as well as the ability to check the mold halves
themselves for design/tryout/re-engineering/repair work they
might coordinate internally in the future.
The ability for the Crysta-Apex CMM to handle this type of
tight and unique angled measurement is not an issue due to a
wide range of probe styles/sizes used, as well as an indexable
head probe system that can be easily and quickly configured in
hundreds of different positions.
They operate the Crysta-Apex CMM in multiple modes. The
joystick-driven mode is used for one-off types of checks and
programming. It can also be operated in an unattended mode
when it becomes a daily part checking requirement (build the
fixture, write the program, CNC automatically runs).
Important Features
Measuring range of 27.75" (705mm) X-axis; 27.75" (705mm)
Y-axis; 23.81" (605mm) Z-axis
Measurement resolution to 0.000004" (0.0001mm)
Scanning and touch-trigger probing capabilities
Renishaw Indexable Head Probe System (PH10MQ): 720
indexable positions that take less than 4 seconds to complete
Continuous Scanning Probe
Comprehensive MCOSMOS C3 Software System
Full factory support, training, installation and warranty
A Self-Proclaimed Mitutoyo Shop
YAMIs technology brand loyalty is found beyond CMM appli-
cations. Other Mitutoyo technologies are utilized for their cus-
-
moldmakingtechnology.com 23
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tomers specialized metrology needs. One additional example
is found with the BAS part that required specific quality control
checks not capable with existing equipment. For example, a
2mm central radius is checked via a Mitutoyo Contracer CV
3100 profile contour measuring machine. This tight +0/-.2 mm
tolerance check could not be measured by a radius gauge or
other type of measuring device because of the intricate design of
the part, according to Parker. On that same BAS part, an impor-
tant metal insert is checked to a 12 RZ roughness level with
Mitutoyos Surftest SJ-400 portable surface roughness tester.
Critical to that part is the metal inserts roughness level because
the part is ultrasonically welded in downstream operations and
the overall surface must meet a precise surface roughness to
provide a tight fit with its mating part.
Parker appreciates the user-friendliness that both machines
provide, especially in the touch screen capabilities of the
color-graphic LCD and the high-speed printer that prints out
measurement results right at the work space. Both machines
provide a fairly small footprint that works well in their gauge
rooms limited space.
Lessons Learned
The addition of production equipment (e.g., molding machines
and automation) isnt the only solution when trying to grow
your molding companys overall business volume and process-
ing capabilities. In YAMIs case, the appropriate strategy in pre-
cision measurement equipment additions helped them satisfy
customer quality and productivity levels. And the addition of
future in-house mold building/repair/engineering capabilities
will help serve their customer base even better.
For more inFormation:
Mitutoyo America Corporation / (630) 820-9666
info@mitutoyo.com / mitutoyo.com
Yahagi America Molding, Inc. / (270) 749-3000
yahagi.webs.com
ContrIbutor
Dave Schwab is a CMM Applications Engineer for Mitutoyo America Corporation.
-
The Event for Mold Manuf
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Cutting Tools
26 MoldMaking Technology April 2013
By Troy Stashi
Proper cutting action
and chip formation save time,
money and ensure a stable process.
Phot
os a
nd f
igur
es c
ourt
esy
of S
andv
ik C
orom
ant.
Video
Access video
at end of article.
We have all been guilty of reaching for whatever tool
is closest to us to complete a basic milling operation,
thinking we can get by without optimizing the process.
We have also all experienced the resulting poor finish, and that
horrible soundan audible chastisement of our having cut cor-
ners. However, the go-to corrective method of turning down the
feed only masks the real problem, and slows productivity.
When entering into a cut directly, vibration is introduced into
the machining process. This vibration leads to shortened tool
life, poor surface quality and a process that has to be constantly
monitored because tool life cannot be predicted confidently.
Figure 1 shows how the thick chip exists when the cutter leaves
the machining area as it rotates. Also, the tool is under the high-
est loador tool pressurewhen this occurs. This tool pressure
is then very quickly released and causes the milling cutter to
have a slight wobble as the next insert in the cutter body comes
back into the machining process; and, the tool pressure again
increases and loads up the machine spindle bearings again.
All this happens at a very high rate of speed and the result is
a rattling sound until the center line of the cutter is past the
edge of the mold being machined. Once the cutter has moved
to this position, a thin chip on exit occurs naturally. There you
can easily see the difference in thickness of the lines at the fur-
thest point on the right side.
When using the roll-in technique (see Figure 2); however, thin
chips will exit the cutter from the very start of the machin-
ing process, regardless of milling cutter center line position.
This eliminates the tool pressure fluctuation, and loading and
unloading of the machine spindle bearings.
Essential Cutting Strategies
For Mold MachiningWithout the right application techniques, even the best tools can fall short
of their potential. Heres a look at a few key cutting strategiesthick chip,
roll-in technique, radial ramping, helical interpolation, cutter positioning,
conventional vs. climb milling and constant cutter engagement.
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moldmakingtechnology.com 27
The golden rule of milling with carbide
inserts: A thick chip upon entry and a thin
chip upon exit. Always ensure the smallest
chip thickness possible when exiting a cut.
and the thin chip on exit allows this compressive state to be
released on a gradual basis. Again it all happens very quickly,
but carbide inserts are not good at releasing the compression of
a thick chip all at oncethe sudden change in load from com-
pressive to tensile causes carbide chipping on exit. Meanwhile,
for a small engagement typically found in profiling operations,
25 percent of the cutter diameter in cut is optimal for tool life
and productivity.
Its important to keep in mind the potential effects of thick
chips on exit due to cutter position over the mold. Most manu-
facturers center the cutter over the center of the part and thick
Workpiece entry straight inthick chip on exit. Before the
cutter is fully engaged there are thick chips on exit resulting in
edge failure, poor tool life and vibration.
Figure 1
Workpiece entry roll into cut. Rolling into
cut keeps chip thin on exit, reducing vibrations
and giving best tool life.
Figure 2
So in the end, the rolling-in tech-
nique not only eliminates the vibra-
tion problem to increase the tool
life; and therefore, the productivity
of the machining process, it also
reduces machine spindle bearing
wear and yields a more predictable
machining process. Such predict-
ability allows the machine operator
to walk away from the process with
confidence, knowing there will not
be any surprises while his/her back is turned.
Another option for generating thin chips on exit is radial
ramping. If the milling cutter is introduced into the machin-
ing process on a 20 to 30 angle, the same effect takes place as
does with the roll-in technique. This is an option for simplified
machine programming.
Helical interpolation (see Figure 3) is a technique that is used
for machining a pocket or creating a hole in the mold with a
milling cutter. The milling cutter starts out above the mold
and is moved in a circular path as it is lowered into the mold
and begins the machining process. Its a bit easier to get the
thin chip when doing this operation because all it requires is
one additional circular movement
of the milling cutter from above
the mold. The cutter will just start
a little higher above the mold and
move in a counter clockwise cir-
cular path as it progresses towards
and into the surface of the mold
itself. Many people dont perform
this extra step and experience the
same negative effect of vibration,
shortened tool life, etc.
Cutter positioning over the
mold goes a long way in getting
the precision you need. For large
engagement face milling, 70-per-
cent engagement is optimal. It
gives the carbide inserts time to
compress with the tool pressure,
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Cutting Tools
28 MoldMaking Technology April 2013
Figure 4
process, so re-position the cutter and program to ensure thin
chip on exit at all times. Again, many manufacturers pro-
gram directly over the voids (see Figure 5, top). Not only
does this introduce the vibrations and instability discussed
earlier, it also introduces conventional milling and climb
milling in the same path, magnifying these undesirable
conditions. Instead, they should be using the paths on the
right. Roll-in, keeping constant engagement and thin chip
on exit (see Figure 5, bottom).
For moldmaking there is a lot of profile work done to cre-
ate the intricate features of the molded component. The
same techniques of roll-in and constant engagement by pro-
grammed radius movements of the cutter create the thin chips
on exit that maximize productivity (see Figure 6). There are
also many internal corners in moldmaking, and anyone can
tell you the cutter will normally vibrate when reaching the
corner. The arc of engagement when approaching the internal
corner should be about 50 degrees to remain problem-free.
However, as the milling cutter enters the corner that arc of
engagement increases to 140 degrees due to the material that
exists in front of it, where it hadnt been before. Then, many
manufacturers will make a 90-degree change in direction to
start machining another area of the mold. This causes vibra-
tion because the arc of engagement has increased beyond
90-degrees and the cutter has unloaded.
This means the programmed change in direction has actu-
ally caused the machine to stop moving the cutter altogether,
LeArn MoreVisit our Cutting Tools Zone for more information on end mills,
drills, inserts, spindles, toolholders, fuids and coatings.
Go to moldmakingtechnology.com/zones for a complete list.
Cutter path face milling. Keep cutter constantly engaged.
Rolling into cut when circular interpolating keeps chips thin on exit and
engagement angles lowreducing vibrations and allowing highest productivity.
Figure 3
chips result on exit. Instead, the process should be optimized
to ensure the lowest chip thickness.
Its also important to distinguish between climb milling and
conventional milling. Both are a direct result of the position of
the cutter over the mold. With conventional milling, the cutter
is offset to the right side, again resulting in thick chips on exit.
When using a climb milling pass, the cutter is offset to the left
and chips are thin on exit. This process is referred to as climb
milling because the cutting action is actually pulling the cutter
through the machining process. When conventional milling,
the cutter is being restricted by the compressive forces.
Constant cutter engagement is another path to optimized
productivity. This is to say that the width of cut (width of
material being machined) remains the same throughout the
machining process. Most often in moldmaking, the milling
cutter is moving around the mold creating different fea-
tures. This should be done using programmed radius move-
ments of the milling cutter, and not a series of straight line
moves (see Figure 4).
This is what many manufacturers do, but this is not a good
situation because it loads and unloads the spindle, introduces
the vibration, shortens tool life and greatly reduces overall
productivity. When the roll-in technique is used to enter the
component and then the cutter is moved in a series of radius
movements to turn corners, this keeps chips thin on exit,
keeps the cutter engagement equal (even in the corners) and
provides stability to the process.
Machining over slots or holes will result in an insecure
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moldmakingtechnology.com 29
For more inFormation:
Sandvik Coromant / (800) 726-3845
sandvik.coromant.com
Contributor
Troy Stashi is an Industry & Application Specialist, Automotive/Milling for Sandvik Coromant.
Videoroll in techniquehttp://short.moldmakingtechnology.com/rollintech
so tool pressure is lost and vibration starts. Then the cutter
takes off in another direction and the tool pressure and load
are increased once again. During the increase in tool pressure
and spindle load, the cutter will continue to vibrate until the
load level is high enough to stabilize the spindle. The correct
process would be to use programmed radii to maintain constant
engagement, spindle and cutter load and to avoid stopping
the machine (see Figure 7). When using a programmed radius,
program using the largest radius possible while maintaining the
constant cutter engagement principle discussed earlier. Ideally,
you would like the programmed radius to be the same as the
cutter diameter, but no lower than 75% of the cutter diameter.
This will ensure favorable cutting conditions.
Summary
Without the right application techniques, even the best tools
can fall short of their potential.However, by keeping the gold-
en rule of milling in mindaiming for a thick chip upon entry
and a thin chip upon exit of moldmaking applicationsthese
processes should ensure the smallest chip thicknesses possible
when exiting a cut. Proper cutting action and chip formation
save time, money and ensure a stable process.
Cutter path when profling external corners. Program radius movements
to drive the cutter around a corner instead of stopping to change machining
direction.
Figure 5
Chip formation and cutter positioning. Machining over slots or holes in
the component will result in an insecure process. Re-positioning the cutter and
machining around these will increase security and maximize performance.
Cutter path internal cornersend milling. Machining into corners is a
vibration hot spot; correct programming of corners will give increased tool life
and allow increased cutting data; consider the change in the arc of engagement
when straight cutting into corners.
Figure 6
Figure 7
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Inspection/Measurement
30 MoldMaking Technology April 2013
Pairing GD&T with Industrial CT
By Spiro Spiliadis
GD&T analysis using industrial CT scanning for internal geometries
(an aluminum casting).
In the 1960s Theodore Levitt said, People dont want a
quarter-inch drill, they want a quarter-inch hole. Levitts
statement provided us with the understanding that people
who buy products and services do so to accomplish a task
or achieve a goal. These tasks or goals have less to do with
the technology and more to do with the outcomewhat has
come to be known as jobs-to-be-done.
In order to provide you with a solid value proposition for
GD&T through industrial computed tomography (CT)
scanning, I wont present you with what industrial CT is,
how it works or a history lesson on the technology itself. Id
rather present the jobs-to-be-done approach. The notion
is simple, You dont really buy products or services, you hire
them to do a job.
Jobs-to-Be-Done Approach
Turning to industrial CT scanning is an important and viable
step. However, hiring the service providers who can handle
such complex projects is taking that step toward the outcome
of a jobs-to-be-done approach. Industrial CT scanning services
have shown to help moldmakers based on three determining
factors: (1) accuracy, (2) repeatability and (3) savingsboth in
terms of time and costwhen it comes to highly complex part to
print projects, which require numerous GD&T points inspected.
Who really cares about the drill, give me the hole! What moldmak-
ers want most is a smooth transition from part to print request to
a part to print report. This is accomplished by scanning, analyzing
and measuring your part, so that you can make a qualified decision
within a shorter time frame and get to production faster. This allows
you to receive a value-added solution because it increases the value in
actionable data to drive performance improvement, and at the same
time it upgrades standards in quality control.
Moldmakers who handle highly complex geometrical parts on
a regular basis know all too well that anticipating such a highly
complex GD&T project can be time consuming, difficult to mea-
sure and not cost effective at all.
Jobs-to-be-done + GD&T + industrial CT =
successful internal complex geometry inspection
Industrial CT scanning has become
an integral part in GD&T and how the
internal measurement of complex
component parts should be facilitated.
Helps with
Moldmakers Part
to Print Projects
Imag
es c
our
tesy
of
JG&
A M
etro
logy
Cen
ter.
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moldmakingtechnology.com 31
GD&T through Industrial CT
When it comes to GD&T, measuring for internal features on
component parts has proven to be difficult. Industrial CT
scanning has become an integral part in GD&T and how the
internal measurement of complex component parts should be
facilitated.
Turning to industrial CT for your GD&T projects is a viable
measurement solution for obtaining a complete and accurate
3-D model of the parts internal and external geometries.
Complex parts are scanned in a free-state environment, allow-
ing for both external and internal components to be validated
quickly and accurately without destructive testing.
Once the scan is completed the GD&T program is writ-
ten around the scan data set and referenced to the part print.
From there, the GD&T program is instantaneously applied to
future scans of the same or mirrored part.
Working off a Gaussian least squares model, repeatability
is much higher and measurement programs can be applied to
multiple parts. So once a program is written it can be applied
to subsequent parts as well. Since the software is a virtual
environment, a coordinate system can be created however the
user wants. With its intuitive menu and its approach of apply-
ing sub objects for measurement, the computed tomography
software provides the ability to adjust a sub object, which is then
updated down the chain.
For example, cylindricity call outs are extremely difficult, time
consuming and costly to measure with alternative methods. The
cylindricity function through industrial CTs software with a
CT dataset makes performance calculations as easy as finding a
standard dimension or radii.
Additional value-added features of measuring GD&T through
industrial CT software include:
GD&T with CT datasets can be performed on parts less than
1 millimeter in size
GD&T with CT datasets can be performed on small intricate
parts in 3-D as opposed to 2-D
GD&T with CT datasets can be performed on different
material densities inside a part of an assembly
Industrial CT scanning works by taking several hundred to
several thousands of 2-D x-ray images covering 360 degrees. Once
the scan is completed the 2-D x-ray images are reconstructed in
3-D, giving you the opportunity to see the external and internal
features of the part, inspect for defects, and capture exact geo-
metrical measurements for comparison and metrology purposes.
Summary
GD&T has been an essential tool for establishing design intent,
to make sure that parts meet the requirements of fit, function
and interchangeability. Industrial CT scanning is setting a new
standard in qualifying pre-production parts quickly and accu-
rately while reducing inspection costs. This is achieved by using
the right technology, expert analytical support, and scan data
calibration to ensure accuracy.
The accuracy, efficiency and reduced turnaround time dem-
onstrate that industrial CT scanning will continue its trend of
becoming a required tool for inspection, as industry leaders are
identifying both the value in inspection standards and the cost
savings it offers.
contributor
Spiro Spiliadis is Marketing Manager at Jesse Garant & Associates/JG&A Metrology Center.
For more InFormaTIon:
JG&A Metrology center / (855) 962-5300
spirospiliadis@gmail.com / jgarantmc.com
LeArn moreVisit our Inspection/Measurement Zone for more information on
coordinate measurement machines and software, probes, vision
systems, balance machines, calibrators and scanners.
Go to moldmakingtechnology.com/zones for a complete list.
An insulin pen showing internal geometries via GD&T analysis using industrial CT scanning.
-
Stainless
From left to right:
Bryan McIntosh
Operations Manager, Big 3 Precision Products, Inc.
Scott Gibson
Plant Manager, Big 3 Precision Products, Inc.
Charlie Goodwillie
Sales Director - Manager of Special Accounts,
Edro Specialty Steels, Inc.
EDRO Engineering and Specialty Steels, Inc.Call: 1-800-368-EDRO
www.edro.com
RoyAlloy - Boost in Production and Overall ValueBig 3 Precision Products provides complete blow mold tooling systems. We pride ourselves
on quality workmanship, service, on time delivery and building long term relationships.
It allows us to remain a leader in the injection Blow Molding and Injection Stretch Blow
Molding industries. The products, service and relationship we have with EDRO re ects that
of our own mission goals.
Weve chosen EDROs RoyAlloy Stainless Steel for use in all our Die Sets, Machine Parts and
Holder applications as the quality of this product has given us superior performance in the
eld as well as improved ef ciencies during manufacturing.
Weve built the largest cavitation molds in our industry and are challenged every day with
demands for higher cavitation and speed to market. RoyAlloy has helped us meet those
challenges, its corrosion resistance, toughness, ductility and dimensional stability in original
component manufacturing as well as part molding has proven itself in the most demanding
Injection Blow and Injection Stretch Blow Molding applications.
This is exactly the expectations our customers have for our products and why we will
remain with EDROs RoyAlloy.
Scott Gibson Plant Manager, Big 3 Precision Products, Inc.
RoyAlloy Stainless is covered under Patents 6,045,633 and 6,358,334
-
moldmakingtechnology.com 33
Hot Runners
Energy Savings In Multi-Cavity Molds
By Massimo Rossi
Constant research into thermo-
plastic materials, and offering
improved performance as a conse-
quence of heightened technical and economic
needs, is leading to an ongoing evolution in mold-
ing. Research involves not only the process but also
the machine and mold, which is in line with the growing
aim to optimize all phases of the production process. The
moldconsidered the fundamental part of the systemis
similarly developing at the same pace. Of particular interest is
detailed research into energy savings, especially regarding the
hot runner.
Energy Analysis
During some hot runner development R&D, finished parts
were analyzed with the aid of specific software to simulate the
systems thermal, fluid dynamic and structural behavior during
the design and engineering stage. System thermal homogene-
ity was also assessed during this analysis phase, estimating
cycle energy consumption and checking any pressure drop and
weight balancing of shots (see Figure 1).
In addition to the use of such instruments, it is essential to
take advantage of those with hands-on experience and exper-
tise, who pay close attention to simplifying system maintenance
and energy-saving issues during any new hot runner product
line development.
Keep in mind that energy savings is not limited solely to the
system itself (thanks to reduced thermal dissipation between
system and hot half), but also to reducing scrap during system
restart.
Hot runners with excellent thermal stability combined
with optimal canalization design are an ideal solution for
many applicationsincluding the medi
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