High-speed milling of molds and precision complex parts
With the boom in the automotive market, the replacement of automobiles has become faster and faster, requiring new product development cycles to be as short as possible. The high-speed milling process has high efficiency and can cut complex profile cavities. In particular, combined with flexible machining methods such as vertical and horizontal conversion 5-axis linkage, it is an excellent solution for rapid manufacturing of prototype parts.
II. Auto parts mold processing
III. Processing automotive interior parts mould
The replacement of the car is not only reflected in the improvement of performance, but also in the update of the appearance and interior parts of the car. Most of the automotive interior parts are injection molded parts, and the consumption of the mold is large. High-speed milling can improve the manufacturing precision of the mold and prolong the service life of the mold, thereby improving the quality of the injection molded parts.
It can be seen that high-speed milling has shown great technical advantages in the processing of automotive parts molds and interior parts molds. In terms of processing technology, high-speed milling is mainly used in the following aspects in automotive mold processing.
1. High-speed milling machining electrode
The electrical discharge machining process basically requires two electrodes to machine a workpiece. For better electrical discharge machining, it is necessary to duplicate the same electrode and to distinguish between roughing and finishing electrodes by surface quality. A well-consistent electrode reduces the time required for electrical discharge machining. Traditionally milled electrodes require manual polishing with poor consistency, and the manually polished electrodes always have sharp corners, while tip discharges affect the quality of electrical machining. The high-speed milling of the electrodes eliminates the need for manual polishing, and the near-perfect consistency between the roughing and finishing electrodes optimizes the efficiency of the electrical discharge machining. At the same time, high-speed milling can process thin walls, so that ribbed integral electrodes can be processed. This eliminates the cumulative position error caused by multiple clamping in conventional milling, which saves time and improves quality.
Processing method - total number of processes - total time (h) - groove processing (h) - machining accuracy (mm) - surface roughness
Traditional milling processing—22—256—179—±0.2～±0.5—Ra1.6
High-speed milling processing—17—120—44—±0.10—Ra0.4
2. Roughing and semi-finishing of the mold
Since high-speed milling can be machined directly on hardened steel, it is theoretically possible to mill the mold directly. However, when the mold cavity has special requirements, it also needs the cooperation of electric machining. Therefore, the roughing and semi-finishing of the mold cavity can be performed by a high-speed milling machine after the material is heat-treated. With a small margin left, the final finishing of the mold is done by electrical discharge machining.
3. Direct high-speed milling to complete hardened steel mold
This method is the biggest manifestation of the advantages of high-speed milling in mold processing. Take the high-speed milling crankshaft and connecting rod forging die of Mikron in the commercial vehicle forging factory of Dongfeng Motor Co., Ltd. as an example.
The traditional milling process is: Roughing of shape → profile milling roughing groove → heat treatment → shape finishing → numerical control electric spark rough, finishing groove → fitter polishing groove → surface strengthening treatment.
The process of high speed milling is: Roughing of shape → Heat treatment → Shape finishing → High-speed milling groove → Surface strengthening treatment.
The use of high-speed milling direct machining to complete hardened steel molds has obvious processing advantages. It reduced total processing costs from more than 27,000 yuan in traditional processing to 22,000 yuan.