In modern mold production, the demand for both aesthetic appeal and functional performance of plastic components continues to rise. As a result, the internal layout and shape of these parts have become increasingly complex. The proportion of parting surfaces has grown significantly, leading to more intricate mold design plans. All of these factors place higher demands on mold manufacturing techniques, not only requiring high precision and excellent surface finish but also emphasizing efficient and elegant processing methods.
With the continuous advancement of high-speed machining technologies, especially in the development of machining tools, CNC systems, tooling solutions, and CAD/CAM software, high-speed machining has become widely adopted in mold cavity processing. One of the most significant developments in the mold industry is the integration of CNC high-speed cutting with manual labor. This approach represents an advanced manufacturing technique that enhances efficiency, quality, and cost-effectiveness. Compared to traditional boring processes, high-speed cutting offers much higher cutting speeds and feed rates, and the cutting mechanism itself differs significantly.
High-speed cutting improves the overall quality of the cutting process, increasing the metal removal rate per unit power by 30% to 40%, reducing cutting force by 30%, and extending tool life by up to 70%. Additionally, it minimizes heat generation on the workpiece and reduces low-order cutting vibrations almost entirely. As cutting speed increases, the material removal rate per unit time improves, shortening processing time and enhancing the overall outcome. This leads to a reduced manufacturing cycle and improved product competitiveness.
Moreover, the small cutting force associated with high-speed machining helps reduce thermal stress deformation in the workpiece, improving the rigidity and feasibility of cutting thin-walled parts. Due to the low cutting force, the increased spindle speed ensures that the cutting system's frequency is far from the machine tool’s natural frequencies, minimizing surface roughness. When machining high-hardened steel (HRC 45–65), high-speed cutting can replace EDM and grinding processes, eliminating the need for electrode manufacturing and time-consuming electrical operations, thereby significantly reducing the workload of fitters.
High-speed milling is also effective for thin-walled mold components, which are increasingly in demand. In high-speed CNC machining centers, molds can undergo multi-step processing in a single setup. This technology has transformed traditional, labor-intensive processes like “annealing → milling → heat treatment → grinding†or “EDM → manual polishing,†replacing them entirely. High-speed machining enables direct machining of hardened mold cavities, especially for semi-finishing and finishing stages, and is widely used in EDM electrode production and rapid prototyping.
Practical mass production has shown that high-speed cutting can reduce subsequent manual grinding time by about 80%, save around 30% in labor costs, achieve mold surface accuracy of 1 micrometer, and double the tool cutting efficiency.
Second, high-speed milling machines:
High-speed cutting is a key direction in the evolution of machining technologies. It has advanced alongside developments in fundamental skills such as CNC, microelectronics, new materials, and innovative designs. Due to the unique requirements of mold processing and the characteristics of high-speed machining, the related technologies and process systems—such as machine tools, CNC systems, end mills—must meet higher standards than traditional mold machining.
1. High-stability machine support structures
The supporting components of high-speed cutting machines, such as the bed, must possess excellent dynamic and static stiffness, thermal stability, and optimal damping properties. Most machines use high-quality, high-rigidity gray cast iron for structural parts, while some manufacturers incorporate polymer concrete into the base to enhance vibration resistance and thermal stability. These features ensure machine accuracy and prevent tool vibration during cutting. The use of closed-bed designs, monolithic casting, symmetrical layouts, and dense ribs further improves machine stability. Some companies are also using modal analysis and finite element simulation in their R&D to optimize the structure, making the support components more stable and reliable.
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