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Feature Articles


Graphite or Copper? Part 1

Identifying the differences in cost, detail and performance between graphite and copper will help you select the appropriate electrode material for specific EDM applications.

Controlling Cutting Tool Cost with Hybrid Geometries

Why purchase redundant tooling and risk losing control of your manufacturing costs? Hybrid cutting tool geometries allow you to perform multiple machining applications with one tool.

Systems Engineering Meets Moldmaking

A combination of systems engineering and systems integration approaches improves communication, which yields better mold manufacturing overall.

Competition is Good

Losing business overseas motivated this moldmaker to re-engineer its tools, improve its processes and stand by its customer, ultimately winning the business back.

In the Trenches: Taking Action

In repair, there are no mistakes, just educational experiences.

Benchmark Your Injection Molding Simulation

Use benchmarking to gain confidence in your modeling, material and simulation capabilities, then use the simulation results to guide future design.

Moldmaking Opportunities in Brazil, Russia, India and China

Use this data and analysis to help develop a strategic vision for what foreign markets you should explore to grow your sales beyond the U.S.

Cutting the Impossible

A new approach to machining deep 3D cavities and cores.

From The Editor


Taking That First Step

They say the first step is always the hardest, but you have to take it to change the direction you are headed.

Your Business


Finding, Training & Retaining Employees - Part 11 of a Series

The value of a training needs analysis.

MoldMaking Business Index


Total MBI for June 2014

54.0

Case Study


Taking the Next Step Toward Five-Axis Efficiencies

This moldmaker’s latest five-axis machining center has improved cycle times and surface finish on certain parts while freeing older machines to process other work.

Simplifying Work Flow Management

This moldmaker discovered how new business strategies can help better predict, schedule and manage job flow, especially in the cloud.

End Market Report


Aerospace and Energy/Power Generation

Aerospace industrial production is poised for growth and energy-related manufacturing remains a strong part of the American economy.

Tip of the Month


How to Bridge the Gap with Aluminum Tooling

Whether you call it bridge tooling, soft tooling, pilot production, semi-production or aluminum production tooling, it still refers to producing pre-production quantities of plastic products with potential final part volumes in the millions.

Product Focus


Machining Center Suited for Micro-Mold Milling

Willemin-Macodel will display its 701S machining center, which is designed to offer sub-micron precision for micromachining applications such as milling of micro-molds.

Small Thread Mills Cut Tool Breakage, Part Damage Risk

Sandvik Coromant will showcase its CoroMill Plura thread milling cutters, which are designed to offer reduced tool breakage and component damage compared to conventional taps.

Carbide End Mills Cut Cycle Times in Moldmaking Ops

Subsidiary Niagara Cutter will show a selection of rotating solid carbide tools in Seco Tools’ booth, including its MZN 410R and 510R high-feed end mills designed to reduce cycle times in moldmaking operations on hardened steels, cast irons and super alloys.

VMC Offers High Rigidity, Heavy Cutting Ability

Okuma will introduce its Millac 852V vertical machining center, designed to offer high rigidity, heavy cutting ability and high operability.

Three-Axis Machines Suited to Moldmaking Operations

In addition to crowning a winner to its Chipmaker Challenge contest, Hurco will display two machines said to be of particular interest to moldmakers: the three-axis VMX42HSi and VMX6030i milling centers.

Improvements to CAM System Designed to Boost Cutting Time

Delcam will launch the 2015 version of its PowerMill CAM system, which includes improvements to the Vortex area-clearance strategy that are designed to produce higher feed and material-removal rates for reduced cutting time.

Wire EDM Provides In-Process Inspection

GF Machining Solutions will spotlight its CUT 200 Dedicated wire EDM for mold and die, aerospace, and medical applications.

Large-Part EDM Offers Increased Travel

One of the machines on display in MC Machinery Systems’ booth will be its newest MV series EDM, the MV4800 Advance, which features a cylindrical drive and increased travel, making it well-suited for larger part production.

Control Calculates Optimum Speed for Quality Surfaces

Heidenhain will highlight its redesigned TNC 640 control, which features improved 3D program verification graphics and a “dynamic prediction” function that is said to calculate the optimum speed to achieve precise and smooth surfaces. The control offers both milling and turning capability.

CAD/CAM Update Boosts Machining Finish Quality

CGS North America will demonstrate how the latest version of its CAM-Tool CAD/CAM software can machine a mold or die with minimal to no polishing.

Multitasking Machine Combines Vertical, Horizontal Capabilities

Doosan Infracore will debut its new Puma SMX 3100 S multitasking machine, which integrates the capabilities of a vertical machining center and a horizontal turning center into one platform.

Wire EDMs Offer Versatility, Low Operating Cost

Makino will showcase its U3 and U6 wire EDMs, which feature HyperCut technology and Hyper-i controls designed for ease of operation, versatility and low operating cost.

EDM Manual Available Online or as Downloadable App

Poco Graphite will display the latest revision of its EDM Technical Manual, published in an online format for web access, and also now available as a downloadable app on Android and iOS systems.

New Machines Added to Lineup

Haas Automation will exhibit a number of machines at IMTS, including the new ST-55 large-bore turning center and UMC-750SS five-axis universal machining center.

Flat-Face Tips Drill Suited for Flat-Bottom Hole Making

Ingersoll has added a flat-face tip for flat-bottom machining to its Gold-Twist drilling line.

VMC Provides Fast Rapid Traverse Rates

Designed to meet and exceed the requirements of the metal-cutting industry, Hardinge’s new Bridgeport Conquest V1000 vertical machining center provides fast rapid traverse of 1,693"/min. on the X and Y axes, and 1,417"/min. on the Z axis.

Miniature Optical Encoder Promotes Signal Stability

With a read head as small as 6.7 × 12.7 × 20.5 mm, Renishaw’s Atom non-contact optical linear and rotary incremental encoder system uses filtering optics with automatic gain control and automatic offset control for high signal stability and dirt immunity.

Automated Cell to Machine Mold Components

Visitors to Absolute Machine Tools’ booth will be able to watch an automated machining cell produce multiple cavity and core components for the mold and die industry.

Horizontal Boring Mill Cuts Tough Materials

Chevalier will exhibit nine machines at IMTS, including its FBB-110L series T-type horizontal boring mill, which offers a 120" × 83" × 80" machining work zone suited for heavy-duty, high-precision applications.

Urethane-Covered Bearing Rollers Offer Non-Marring Operation

Fixtureworks will showcase its lineup of workholding and machine tool components, fixturing accessories, and material handling products, including the Fairlane Products line of urethane-covered bearing rollers.

Toolholding, Workholding Technology on Display

Exsys Tool will exhibit a range of toolholding and workholding technology, including its Preci-Flex modular quick-change tooling system; Eppinger PSC C3, C4 and C5 connection base holder; Deco-Flex modular adapters; and modular Gressel vises.

Gundrills Enable High Table Feeds

Iscar Metals will showcase its SumoGun gundrills for deep drilling applications, which enable replacement of the drilling head inside the machine without the need to remove the drill for head indexing.

Single-Base Plates Secure Workpieces to Machines

Erowa Technology has added single-base plates to its line of MTS multi-base plates for palletizing workpiece holders, vises and fixtures.

Vertical Jig Borer Suited for Accurate Mold/Die Machining

Methods Machine Tools will spotlight the Yasda YBM 640V3 three-axis CNC vertical jig borer, designed for high-speed, precision boring and milling in mold, die and complex component manufacturing.

Laser Welding System Suited for Mold, Tool Makers

O.R. Laser will demonstrate its HTS EVO mobile laser welding system, developed specifically for mold, and tool and die makers, as well as mobile service providers.

Mobile Simulation App Offers Remote Access to Machining

Spring Technologies will demonstrate the mobile system it has developed for its flagship NCSimul Machine simulation software and Player 9.1 reviewer.

Automated Cell to Demonstrate Machining of Mold Insert

In addition to a variety of machines that offer rigid linear motor technology, visitors to Sodick’s booth will be able to see “live” machining of a mold insert through the integration of electrode production, EDM and high-precision, high-speed milling in one automated cell.

End Mills Feature Pull-Out Protection

Haimer will showcase new Power Mill end mills that feature the company’s Safe-Lock interface, which is designed to act as a “seatbelt” to protect against pull-out from the holder.

CNC Simulation Software Can Be Integrated with CAM

CGTech will feature the latest version of its Vericut CNC machine simulation, verification and optimization software, which operates independently, but also can be integrated with CAM systems.

Shoulder Mill Cuts Cast Iron, Steel

Seco Tools will unveil several new tooling products, including a square shoulder cutter designed for roughing and semi-finishing operations in cast iron and steel.

Taps Designed to Thread Difficult Materials

Among the tools Emuge Corp. will highlight are taps engineered for threading difficult materials such as stainless steels, nickel alloys and titanium.

Slitting Cutter Incorporates Grooving System

Walter with exhibit its new Walter Blaxx F5055 slitting cutter, which incorporates technology similar to the Walter Cut SX grooving system.

Tool Setter Measures Small Tools with Micron Accuracy

Marposs Corp. will introduce its new Mida visual tool setter (VTS), designed to measure and verify small-diameter cutting tools to micron and sub-micron precision.

Hybrid Machine Combines Additive, Subtractive Processes

DMG MORI will demonstrate its Lasertec 65 hybrid manufacturing machine, which combines additive and subtractive processes to produce a complete part from powder.

Modular Workholding System Cuts Setup Time

Single Source Technologies (SST) will exhibit the FCS Modular Clamping System (Breyl), designed to provide unrestricted access to five surfaces of the workpiece, enabling operators to spend less time on setups and more time on machining.

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