How to manufacture customized non-standard tools for machining of mold: A Step-by-Step Guide
Introduction The mold base industry plays a crucial role in manufacturing. Mold bases are essential components used in the production of molds for various industries, including automotive, aerospace, and consumer goods. To ensure precise machining of molds, customized non-standard tools are required. In this guide, we will outline the step-by-step process of manufacturing such tools for the machining of molds.
Step 1: Assessing Machining Requirements
The first step in manufacturing customized non-standard tools is to assess the specific machining requirements for the mold. This involves analyzing the mold design, material, and tolerances required for the final product. Understanding the machining needs allows for the creation of an accurate tool design.
Step 2: Tool Design
Based on the assessed machining requirements, a tool design is created. This design includes the selection of appropriate tool geometry, tool material, and cutting parameters. The tool design must ensure optimal performance and efficiency during the machining process. CAD software is commonly used to create the tool design, allowing for better visualization and precision.
Step 3: Material Selection
Once the tool design is finalized, the next step is to select the appropriate material for the tool. The material should have high hardness, wear resistance, and good thermal conductivity to withstand the demands of machining molds. Commonly used materials for non-standard tools include carbide, high-speed steel, and diamond coatings.
Step 4: Tool Manufacturing
The actual manufacturing of the non-standard tool begins with the production of the tool body. This involves using CNC machines, specifically designed for tool manufacturing, to shape the tool body according to the tool design. The tool body is typically made from solid metal blanks or carbide inserts.
Step 5: Tool Coating
To enhance the performance and longevity of the tool, a suitable coating is applied. Coatings such as diamond-like carbon (DLC), titanium nitride (TiN), or aluminum titanium nitride (AlTiN) are commonly used. The coating improves the tool's hardness, reduces friction, and prolongs the tool life.
Step 6: Tool Assembly
Once the tool body and coating are ready, the next step is to assemble the non-standard tool. This includes attaching the cutting inserts to the tool body using specialized adhesives or clamping systems. Careful alignment and positioning of the inserts are essential to ensure accurate machining results.
Step 7: Tool Inspection and Quality Assurance
Before the tool is put into use, it undergoes thorough inspection and quality assurance procedures. This includes dimensional measurements, surface finish analysis, and testing the tool's performance on sample molds. Any defects or inconsistencies are identified and rectified to ensure optimal tool performance.
Step 8: Tool Maintenance and Sharpening
Regular tool maintenance and sharpening are crucial for prolonging the tool's lifespan and ensuring consistent machining quality. This involves periodic regrinding or replacing of cutting inserts, checking for wear and damage, and reapplying coatings when necessary. Proper tool maintenance helps to maintain accuracy and efficiency during mold machining.
Conclusion
Manufacturing customized non-standard tools for the machining of mold bases requires careful assessment, design, material selection, and manufacturing processes. By following this step-by-step guide, companies in the mold base industry can ensure the production of high-quality tools that meet the precise machining requirements of molds.
