Speeding up moldmaking processes

Mold-and-die shops are finding innovative ways to compete with manufacturing operations in traditionally low-cost labor markets with faster metalcutting through high-speed machining (HSM) and improved EDM techniques. GF Machining Solutions' new Smart Machine modules have multiple sensors on the machine to compensate for any type of vibration or heat expansion, so one can hold these types of tolerances. At G.H. Tool & Mold aluminum die-cast molds are cut to high tolerances using GF Machining Solutions' Mikron high-speed milling machines. A design-to-order manufacturing company, G.H. Tool & Mold uses its Mikron HSM 800 milling machines for producing die-cast mold and replacement parts. Part machining cycle times vary anywhere from 30 minutes to eight hours, and tolerances typically run between ±0.0005 and 0.002. Automating moldmaking is key to improving mold machining processes, agreed Clinton Perry, product marketing manager, Delcam plc. Recent improvements in robot accuracies have made it possible for robotics to automate many new processes. PowerMill's automatic mirroring with automotive mold saves users considerable time whenever right- and left-hand versions are needed of a part/tool or machining symmetrical objects. nhancements to PowerMill 2016 include the ability to automatically mirror complete projects in one operation while maintaining key machining characteristics. With TopSolid 7.9 Mold, moldmakers get a package that was fully rewritten in 2009 for native 64-bit multicore processors. The software, which Missler originally developed in the late 1970s as a machine tool manufacturer, offers speed advantages for moldmakers working with very large mold files. CNC Software has expanded its Mastercam Dynamic Motion toolpaths with refined strategies for better control in specific cuts.