In today's mold manufacturing industry, the demand for both aesthetic appeal and functional performance of plastic components is continuously rising. As a result, the internal design and layout of these parts have become increasingly complex, leading to an increase in the number of parting surfaces and more complicated mold configurations. These changes have placed higher demands on mold processing techniques, requiring not only high precision and excellent surface quality but also refined machining methods.
With the continuous advancement of high-speed machining technologies, especially in the development of cutting tools, CNC systems, CAD/CAM software, and related technologies, high-speed machining has become widely applied in mold cavity processing. One of the most significant innovations in the mold industry is the integration of CNC high-speed cutting with manual labor, which represents an advanced manufacturing process that enhances efficiency, improves quality, and reduces costs.
Compared to traditional boring processes, high-speed cutting significantly increases the cutting speed and feed rate, and the cutting mechanism is fundamentally different. This leads to improved metal removal rates per unit power—by 30% to 40%—while reducing cutting forces by up to 30%. Tool life is extended by as much as 70%, and the heat generated during cutting is minimized, resulting in lower thermal deformation and nearly eliminating low-frequency cutting vibrations.
As cutting speeds increase, the material removal rate per unit time improves, reducing processing time and enhancing overall performance. This helps shorten the production cycle and boost the product’s market competitiveness. Additionally, the small cutting force associated with high-speed machining reduces the stress on the workpiece, improving the rigidity and accuracy of thin-walled component processing.
The high rotational speed of the tool keeps the system’s vibration frequency away from the machine tool’s natural frequencies, which results in a smoother surface finish. In the machining of high-hardened steel (HRC 45–65), high-speed cutting can replace electrical discharge machining and grinding, eliminating the need for electrode manufacturing and reducing the time and effort required for polishing.
High-speed milling is also effective for thin-walled mold parts that are increasingly in demand. With modern CNC technology, molds can be machined in multiple steps in a single setup, increasing efficiency and reducing errors. The impact of high-speed machining on the mold production process has been transformative, replacing traditional methods such as "annealing → milling → heat treatment → grinding" or "electrical discharge machining → manual grinding and polishing."
High-speed machining now allows direct machining of hardened mold cavities, particularly for semi-finishing and finishing stages. It is widely used in EDM electrode processing and rapid prototyping. Practical experience shows that high-speed cutting can reduce subsequent manual grinding by about 80%, cut labor costs by around 30%, achieve mold surface accuracy up to 1 micrometer, and double the tool’s cutting performance.
In terms of high-speed milling machine tools, the requirements for the entire system—including the machine tool, CNC control, and end mills—are higher than those for conventional mold processing. The stability of the machine structure is critical. The bed of a high-speed cutting machine must have excellent dynamic and static stiffness, thermal stability, and damping characteristics. Most machines use high-quality gray cast iron, while some manufacturers incorporate polymer concrete to enhance vibration resistance and thermal stability.
Closed-bed designs, monolithic casting, symmetrical layouts, and reinforced ribs are all strategies to improve machine stability. Some companies are also using modal analysis and finite element simulation to optimize the design and ensure greater reliability and performance.
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