Machining Pages 61 to 76 Pg. 5 By Mr. Heng Li He Machining a micron-level precision mold on the first try is difficult to achieve. Machining the mold two or more times is often necessary to reach the required micron-level tolerance. On-machine measurement and intelligent modifica-tion technology integrated into the control of a high-speed machining center is one way to overcome these variables. It has a set of measurement systems in the machine’s control. First, the measurement points are created in the CAM system. Then, after the program is created, the NC code, measurement points and the part’s solid model file are imported into the control. The operator machines the part and then selects the critical measurement points program. An accuracy heat map of the solid model file appears on the control, which visually indi-cates to the operator if the part is within tolerance. The digital processing capability of a high-speed machining center’s CNC system makes machining micron-level precision molds in one pass possible. For example, the proper digital processing capability will acquire data acquisition from vari-ous measuring instruments and temperature sensors to form a closed-loop, on-machine measurement and intelligent modi-fication function, which efficiently and accurately carries out the measurement work on the CNC machine. It’s like having a CMM built into your high-speed mill. Regarding part size measurement, on-machine measure-ment and intelligent modification technology uses a probe that performs a preliminary inspection of the machined work-piece. Like a CMM, the control creates an accuracy heat map and informs the operator if the part is within spec. The opera-tor can also export the measurement results and heat map image with the machining data. Then there is the cutting tool, for which there can be an inherent deviation between the actual cutter size and the theoretical cutter data during manufacturing. Even the most accurate cutting tools have a tolerance. With on-machine mea-surement and intelligent modification technology in conjunc-tion with the CNC system, the operator can use the laser tool calibrator to measure the inherent deviation of the cutting tool’s radius and perform multipoint compensation accord-ing to the cutter’s contour. After each tool is 3D measured, its actual value is automatically stored in the control, yielding more accurate machining results. The operator can also measure cutting tool wear with on-machine measurement and intelligent modification technol-ogy that uses a laser tool calibrator to measure the change in The precise fit of this part was possible with on-machine measurement and intelligent modification technology integrated into the control of a high-speed machining center. cutting tool size due to wear. If wear exceeds a specific range — especially in the finishing process — it is necessary to carry out corresponding correction work to ensure that the follow-ing cutting tool removes the proper amount of material. Tool wear can also lead to uneven surface finish, which causes the workpiece material to be inconsistent with the machining model. On-machine measurement and intelligent modification technology uses a probe to measure the allow-ance according to the set value. Then the detection map of the remaining surface stock is output in real time. This feature directly analyzes the detection data on the machine tool side. Another challenge is manually aligning a workpiece with an imprecise indicator or inexperienced operator that consumes labor time and produces inaccurate results. High-precision machining centers that automatically align the workpiece in X, Y and Z planes are more accurate and reduce setup time. For example, modeling features that define the workpiece coordi-nate system for the machined material improves high-speed machining accuracy. Machine tools are very sensitive to heat when performing precise machining. On-machine measurement and intelligent modification technology can use a probe and standard ceramic ball to judge whether the current machine tool state is stable and make necessary corrections to adjust for a less desirable machining environment. These modification functions also monitor changes during processing by using various sensors built into the machine tool to detect problems and notify the operator. Alerts prevent the machine tool from working in an unstable state and preserve workpiece accuracy. Acknowledgment: Thank you to Jingdiao’s Jason Wong for his contribution to this article. Jingdiao / info@jingdiao.com / us.jingdiao.com FOR MORE INFORMATION FOR MORE INFORMATION 76 MoldMaking Technology — — JULY 2023 Image courtesy of Jingdiao North America. How to Machine Micron-Level Precision Molds in One Try