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1、Die & Mold Machining Seminar19, March, 2002Mitsuhiko KadonoMORI SEIKI Die & Mold Dept.Die & Mold Machining R & D Dept.OUTLINESTAFF : 6 Specialist EngineersRESPONSIBILITIES : TEST MACHININGINFORMATION for CUSTOMERSDeveloping NEW TECHNOLOGYDie & Mold Machining R&D dept.A workshop-like research center
2、open to manufacturers, with a lineup of the latest machines and CAD/CAM environments.Die & Mold Machining Die & Mold Machining R&D dept.R&D dept.(Nagoya building)(Nagoya building)Machining Center for Die & MoldSVD-403SVD-503/40SVD-503/5010 ton injection molding machineSurface grinding machineA works
3、hop-like research center open to manufacturers, with a lineup of the latest machines and CAD/CAM environments.CAD/CAMCADCEUS(UNISYS)CAM-TOOL(G.P.)CAMAND(SDRC)SURFCAM(SURFWARE)Work NC(SESCOI)Edge CAM(PATHTRACE)UNIGRAPH(UNIGRAPHICS) MASTERCAMElectric discharge machineEX8:Die sinking electric discharge
4、 machineQA10:Wire electric discharge machine100 t injection molding machineC JUBILEE 420CIGA No.2 PlantIGA No.2 PlantDie & Mold Machining R&D dept.21. Hot chamber die casting moldsDie&Mold ConstructionDie&Mold Construction KANAGATADIESForging diesPress dies Plastic moldsRubber moldsGlass moldsMOLDCa
5、stingDie casting molds8. Shoe rubber molds9. Tire rubber molds11. Pressed glass molds12. Blown glass molds13. High pressure casting molds(Main molds)14. Shell molds15. Cold box molds16. Low pressure casting molds17. Gravity casting molds18. Lost wax molds19. Lost from casting molds20. Cold Chamber d
6、ie casting molds 1. Injection molds2. Plastic press molds3. Plastic extruding dies5. Plastic blow molds6. Vacuum forming molds7. Compression molds4. Forming moldsA. For TransportationB. For electrical & electronic productsC. For miscellaneous products, packaging containers,etc.22. Hot - forging dies
7、23. Cold - forging dies24. Transfer press diesA. For Transportation productsB. For electrical products25. Progressive dies26. Multi forming dies27. Powder metallurgy dies10. Industrial rubber moldsA. For Transportation productsB. For electrical productsDie & Mold Machining R&D dept.CAMERABUTTONSPOON
8、PLASTIC MOLDREAR VIEW MIRRORELECTRIC TOOL BODYDie & Mold Machining R&D dept.FORGING DIET-JOINTCONNECTING RODPLIERSJOINT PARTSDie & Mold Machining R&D dept.DIE CASTINGVACUUM MOLDALUMINUM WHEELPLASTIC BOTTLEDie & Mold Machining R&D dept.MOTOR PART (PRESS)GOLF CLUB HEAD (ELECTRODE)GEAR (ELECTRODE)Die &
9、 Mold Machining R&D dept.TIRE (DIRECT CUTTING)ARTIFICIAL JOINT (TITANIUM ALLOY)MACHINING SCENE5-AXIS MACHININGDie & Mold Machining R&D dept.TREND OF TEST CUTS FOR DIE & MOLDREDUCING TOTAL TIMEREDUCING TOTAL TIMEHIGH SPEED MACHININGGOOD SURFACE (POLISHLESS)GOOD SURFACE (POLISHLESS)HARDENED MATERIAL (
10、DIRECT MACHINING)NEW MACHINING INSTEAD OF EDM (DEEP NEW MACHINING INSTEAD OF EDM (DEEP SHAPE OR SMALL RADIUS)SHAPE OR SMALL RADIUS)Die & Mold R & D Dept. MilanSingaporeChicagoYokohamaNagoyaREDUCING TOTAL TIMEREDUCING TOTAL TIMEHIGH SPEED MACHININGGOOD SURFACE (POLISHLESS)GOOD SURFACE (POLISHLESS)HAR
11、DENED MATERIAL (DIRECT MACHINING)From EDM to HSMKEY POINTS of Die & Mold MachiningHigh Feedrate (SV-403)CONVENTIONALFEEDRATE F800F1600(SAME PROGRAM)WATER BOTTLE (BLOW MOLD)Material:1049 (Carbon Steel)High Feedrate (SV-403)WATER BOTTLE (BLOW MOLD)RoughDia. 4mm7min. 59sec,FinishedR 2mm50min. 13sec.ELE
12、CTRODE ( SVD-503/40 )High Feedrate (GV-503/5AX)40M39S13M00SS3,000, F750mm/minMold of Boots (Rough machining)S5,000, F2,000mm/min(RUBBER MOLD)High Speed Spindle6H20M3H48MSpindle 10,000rpmSpindle 20,000rpmMold of packageMaterial : A5052 ( Aluminum )Machine : SVD-503/40(VACUUM MOLD)High Speed Spindle84
13、M27S43M44SR1mm Pitch = 0.04mmR2mm Pitch = 0.08mmRy=0.4 micron(Theory)Ry=0.2 micron(Theory)(VACUUM MOLD)90mm33mmMaterial : GraphiteMachining Time6 hours5858min 12secmin 12secELECTRODE ( SVD-503/40 )Customers Machine(SAME PROGRAM)R10mm = 10.0075mm(Measured)Material:SKD11(190*155*75mm)RyRy = 3.5 - 4.7
14、micron = 3.5 - 4.7 micronTotal cycle time = 7 hoursRPRESS FORM DIE ( SVD-503/40SVD-503/40 )No wear : W.C. R2mmELECTRODE ( SVD-503/40 )Cutting Condition S8,000 F750mm/minCELLULAR PHONE ( ACCUMILL4000ACCUMILL4000 )150mmMachining Time : 6 H 48 M6 H 48 MMaterial : NAK80 ( 40 HRC )(PLASTIC MOLD)KEY POINT
15、S of Die & Mold MachiningREDUCING TOTAL TIMEREDUCING TOTAL TIMEHIGH SPEED MACHININGGOOD SURFACE (POLISHLESS)HARDENED MATERIAL (DIRECT MACHINING)From EDM to HSMSURFACE ROUGHNESSRy 20 micronRy 4 micron(IN SAME TIME)RPRESS FORM DIE ( SVD-503/40SVD-503/40 )A part of FUEL TANKMaterial:SKD11(190*155*75mm)
16、RyRy = 3.5 - 4.7 micron = 3.5 - 4.7 micronTotal cycle time = 7 hoursRPRESS FORM DIE ( SVD-503/40SVD-503/40 )RUBBER MOLD ( SVD-503/40SVD-503/40 )142mmMaterial : STAVAX (33 HRC)Machining Time : 2H. 18M.2H. 18M. Roughness : 1 : Ra 1.3 micron2 : Ra 0.5 micron3 : Ra 0.6 micron4 : Ra 0.6 micron1243RUBBER
17、MOLD ( SVD-503/40SVD-503/40 )Rough : Dia.10mm+R2Pitch : XY0.8/Z13.85Rough : R3mm B.E.MPitch : XY1.8/Z0.7Rough : R3mm B.E.MPitch : XY2.0/Z0.5S-Fin : R2mm B.E.MPitch : C.H.=0.02mmS-Fin : R2mm B.E.MPitch : C.H.0.02mmFin : R2mm B.E.MPitch : Pitch : C.H.0.001mmC.H.0.001mmRUBBER MOLD ( SVD-503/40SVD-503/4
18、0 )Cusp height1 micron : 1 H 30 M 28 S ( this case )2 micron : 1 H 11 M 01 S ( 79%)5 micron : 45 M 35 S ( 50% )Machining TimeCUSP HEIGHTRUBBER MOLD ( SVD-503/40SVD-503/40 )CUSP HEIGHTCUSP HEIGHT VS. TIMEDIE CASTING for ALUMINUM ( SVD-503/50SVD-503/50 )220mmMaterial : SKD61(H13)Machining Time : 5 H 0
19、1 M5 H 01 MDIE CASTING for ALUMINUM ( SVD-503/50SVD-503/50 )Rough : Dia.40mm+R6Pitch : XY28/Z1.4Rough : R6 B.E.M.Pitch : XY4.6/Z0.9Rough : R6 B.E.M.Pitch : XY4.6/Z0.9from top to Z-22mmfrom -Z22 to bottomDIE CASTING for ALUMINUM ( SVD-503/50SVD-503/50 )S-Fin : R5 B.E.M.Pitch : XY0.9/Z0.7S-Fin : R5 B.
20、E.M.Pitch : XY0.9/Z0.7from top to Z-16mmfrom -Z16 to bottomFin : R5 B.E.M.Pitch : XY0.5/Z0.5If : Pitch : XY0.25/Z0.15XY0.25/Z0.15Time : 1H09MTime : 2H46M2H46MFORGING DIE ( Crank Shaft : SVD-403SVD-403 )Material : SKD61(52 HRC)140mm200mm115mmREQUIREMENT Ry = 5 micronFORGING DIE ( Crank Shaft : SVD-40
21、3SVD-403 )Material : SKD61(52 HRC)5. side(R2*4BEM)1. Z02. Z-0.463. Z-21.774. Z-25.796. side(R2*16 BEM)7. side(R2*25BEM)8. side(R2*90BEM)REDUCING TOTAL TIMEREDUCING TOTAL TIMEHIGH SPEED MACHININGGOOD SURFACE (POLISHLESS)MACHINING HARDENED MATERIAL From EDM to HSMKEY POINTS of Die & Mold MachiningFORG
22、ING DIE (TEST CUTTING)300mmMATERIAL:HRC60ENLARGED(SVD - 403)CYCLE TIME: 6hr. 47min.MATERIAL : HSS (60HRC)HSS (60HRC)FORGING DIE(TEST CUTTING)(SVD - 403)SETTINGworkpiece0.5mm0.5mm5.0mm1.5 deg.5.0mmPUNCH DIE (SVD - 403)Roundness & surface roughness(D3 HOLE)D4D27R0.2R0.21MATERIAL : HSS (60HRC)HSS (60HR
23、C)Roundness & surface roughness1(Ry)2(ROUNDNESS)Ry = 0.6 micron0.6 micron , ROUNDNESS = 3.3 micron3.3 micronPUNCH DIE (SVD - 403)REDUCING TOTAL TIMEREDUCING TOTAL TIMEHIGH SPEED MACHININGGOOD SURFACE (POLISHLESS)HARDENED MATERIAL (DIRECT MACHINING)From EDM to HSMKEY POINTS of Die & Mold MachiningMAC
24、HINING VS. EDMEDM : * ELECTRODE* LONG CYCLE TIME* SHARP EDGE* HIGH HARD MATERIALMACHINING : * NO ELECTRODE* SHORTER CYCLE TIME* CUTTER RADIUS* HARD MATERIALMACHINING VS. EDM(A PART OF DIE - CASTING)R = 1mmL = 25mmCutterMaterialSKD61(HRC48)MACHINING VS. EDM(A PART OF DIE - CASTING)TOTAL CYCLE TIME :
25、3 hrs. 48min. 18sec.TOTAL CYCLE TIME : 3 hrs. 48min. 18sec.MACHINING VS. EDM(DEEP CAVITY)115mmMATERIAL : 1049Rib Machining ( Dia.1mm x 0.5deg.)MACHINING VS. EDM(DEEP CAVITY)R 3 mm Ball EndmillS = 2,122 min-1F = 424 mm/minTotal machining time6 hrs. 30 min.(Finish = 3 hrs. 50 min.)Cam system : CAM - T
26、OOL C3MACHINING VS. EDM(RIB MACHINING)CUTTER for RIB1.5mm218mmMaterial : NAK55(HRC40)64 x 48 x 48 mmMachining Time : 2 h 20 mRoughness : Ry2.5 micronMACHINING VS. EDM(RIB MACHINING)RoughnessRy=0.9 micronRy=0.7 micronRy=2.9 micronRy=2.4 micron250mmMaterial : NAK80 (40 HRC)Rib Machining ( Dia.1mm x 0.
27、5deg.)1mm10mm Experiment (1) Experiment (1) Rib Machining ( Dia.1mm x 0.5deg.)Rib Machining ( Dia.1mm x 0.5deg.)Roughness (Time)Ry=0.9m(423 min)Ry=0.7m0.7m(123 min)Ry=2.9m( 77 min)Ry=2.4m( 69 min69 min)250mmMaterial : NAK80 (40 HRC)Rib Machining ( Dia.1mm x 0.5deg.)Rib Machining ( Dia.1mm x 0.5deg.)
28、D.O.C=0.05mmD.O.C=0.03mmTool Life ComparisonTool Life Comparison1.Coated + Semi-dry(561m)2.Non-coated+Semi-dry(64m)3.Coated + Water(50m)4. Non-coated+ Water(3m)Material : NAK80 (40 HRC)Rib Machining ( Dia.0.9mm)Zig-zag Experiment (2) Experiment (2) Rib Machining ( Dia.0.9mm)DEPTH = 7mmWIDTH = 0.9mmG
29、roove ShapeD = 0.9mmd = 0.86mml =8mml1 =1.4mmCutter : NHR2(Non-coat) MHR230(Coated)(NISSHIN)Rib Machining ( Dia.0.9mm)(Water-soluble)561.263.62.649.80100200300400500600Tool Life(m)(Semi-dry) Non coated Coated9 TimesMachining ConditionS = 10,000(rpm)F = 200 (mm/min)D.O.C. = 0.015(mm)Run out = 0.004(m
30、m)Cutting LengthRib Machining ( Dia.0.9mm)(In case of “5 m” length groove)(Water-soluble)(Semi-dry)HK$ 236,000HK$ 11,000/5mHK$ 0.44mil/200mHK$ 0.44mil/200mREDUCING TOTAL TIMEREDUCING TOTAL TIMEHIGH SPEED MACHININGGOOD SURFACE (POLISHLESS)MACHINING HARDENED MATERIAL From EDM to HSMKEY POINTS of Die & Mold MachiningThank you very much
