The injection molding process begins by injecting plastic into a mold, which is then rotated along two vertical axes and heated. Under the action of gravity and heat energy, the plastic in the mold gradually and evenly covers, melts and adheres to the entire mold cavity surface to form the desired shape, and then completes the production by cooling and shaping. During the processing and production of injection molds, many injection mold factories will use high-speed cutting technology. So, what are the advantages of using high-speed cutting for injection mold processing?
First, high-speed cutting can improve production efficiency. Compared with traditional cutting methods, high-speed cutting can complete the mold processing process faster. Since the tool is cutting while rotating at high speed, the cutting speed is greatly increased, thus shortening the processing time. This is particularly important for large-scale production, which can greatly reduce the production cycle and improve production efficiency.
Secondly, high-speed cutting can improve processing accuracy. Since the contact time between the tool and the workpiece is short during high-speed cutting and the cutting force is small, the impact on the thermal deformation of the workpiece is small. At the same time, high-speed cutting can also reduce the impact of cutting forces on the workpiece, thereby reducing processing errors. This improves the processing accuracy of the injection mold and ensures the quality of the final product.
In addition, high-speed cutting can also improve material utilization. Since the cutting speed of the tool is faster during high-speed cutting, the contact area between the tool and the workpiece is smaller, so the amount of material removed is less. This means less material is wasted during processing, improving material utilization. This has important implications for cost and resource savings.
Finally, high-speed cutting can also reduce production costs. Because high-speed cutting can improve production efficiency and material utilization, it can reduce time and material consumption in the production process. This reduces production costs and improves the competitiveness of enterprises.
To sum up, using high-speed cutting for injection mold processing has the advantages of improving production efficiency, processing accuracy, material utilization and reducing production costs. These advantages make high-speed cutting an important technical means in injection mold processing and have been widely used and promoted.
In the process of high speed cutting, the tool and workpiece can maintain high temperature, which extends the tool life in many cases. On the other hand, in the use of high-speed cutting, the cutting amount is shallow, and the cutting time of the cutting edge is especially short. This means that the feeding time is faster than the heat transfer time.
Low cutting forces lose small and divergent tool bends. This, combined with the constant machining allowance required by each tool and process, is one of the prerequisites for efficient and safe machining.
Because the typical cutting depth in high-speed cutting of injection mold is shallow, the radial force on the tool and spindle is low. This increases the wear of the spindle bearing, guide rail and ball screw. High speed cutting and axial milling are also a good combination, which has little impact on the main shaft bearing. With this method, you can use a tool with a long overhang and have little risk of vibration.
High productivity cutting of small size parts, such as rough machining, semi finishing and finishing, has good economy when the total material removal rate is relatively low.
In this way, the clamping times of the injection mold processing are reduced. In addition, the geometric accuracy of the injection mold is improved through cutting. At the same time, the manual rest and the trial time can be increased. In addition, CAM and workshop oriented programming are used to help formulate process plans, and the application rate of machine tools and workshops is improved through process plans. Thus, the production cycle is greatly shortened and the production efficiency is improved, thus enhancing the market competitiveness of the injection mold factory.
High-speed cutting is a modern machining technology that has revolutionized injection mold processing. High-speed cutting uses advanced cutting tools and CNC machines to remove material at very high speeds and with great precision. Here are some advantages of high-speed cutting for injection mold processing:
- Faster processing times: High-speed cutting allows for faster processing times, as the machines can remove material at much higher speeds than traditional machining methods. This leads to faster turnaround times and increased production efficiency.
- Improved surface finish: High-speed cutting can produce a better surface finish on the mold, reducing the need for additional finishing operations. The smoother surface finish also helps to reduce friction and wear on the mold, leading to longer mold life.
- Increased accuracy: High-speed cutting machines are highly accurate, allowing for greater precision in mold production. This results in more consistent part quality and tighter tolerances, reducing the need for rework and improving overall efficiency.
- Reduced tool wear: The advanced cutting tools used in high-speed cutting are designed to last longer than traditional tools, reducing the need for frequent tool changes and minimizing downtime.
- Greater flexibility: High-speed cutting can be used to create complex shapes and features that would be difficult or impossible to produce with traditional machining methods. This makes high-speed cutting a highly flexible technology that can be used to produce a wide range of mold designs.
- Cost-effective: Although high-speed cutting requires a significant initial investment in equipment and training, it can be cost-effective over the long term due to its faster processing times, increased accuracy, and reduced tool wear.
In conclusion, high-speed cutting is a modern machining technology that offers many advantages for injection mold processing. It allows for faster processing times, improved surface finish, increased accuracy, reduced tool wear, greater flexibility, and cost-effectiveness. These benefits make high-speed cutting an attractive option for manufacturers looking to improve their mold production processes.