Here are the top 10 videos that MoldMaking Technology’s readers have watched this year!
Venting in Action
A dynamic (versus static) mold-venting valve helps resolve the most common effects of poor cavity venting. Its design is based on a simple mechanical system allowing the gas to escape from a venting hole that automatically closes under the pressure of the plastic flow front. It can be placed inside the cavity where the filling pattern produces gas traps. The venting hole isn't affected by mold deposits, thanks to the high venting capacity counter pressure of the air inside the cavity is dramatically reduced.
Simplifying Mold Open-Close
Watch this demo of the Die-Sep mold separator to learn how quickly, safely and ergonomically molds can be opened and closed in the shop. (Video courtesy of 3M New Ulm, Minnesota)
Challenges presented in doing DTE's work are centered on keeping costs down while maintaining quality. “Time-to-market is increasingly important,” DTE President William Berry emphasizes. “We need to be globally competitive when quality requirements are higher than ever.” Two distinctive capabilities on their new machines each have a great impact on DTE’s time-to-market—linear drives and five axis.
Proving the Advantages of a Servo-Driven Valve Gate System
One innovation for improving sequential injection molding centers around the use of servomotor technology.New servo-driven valve gate systems incorporate a toggle-type mechanism that operates the valve pin position at 90 degrees from the servomotor stroke. A connecting rod between the servomotor and the toggle mechanism (which can be of any length) makes it possible to move the servomotor to what is determined to be an optimal position, including outboard and on the side of the mold. This design enables a much more powerful servomotor to be used to operate the valve gate open/close actuation. A specially designed control system accurately programs the valve pin in eight distinct positions with varying velocity and force in both the opening and closing phases of operation. This provides optimized plastic flow control from each valve gate nozzle into the mold.
5X Tangent Plane Machining
The video starts with the ball end of the barrel cutter cleaning a corner feature, and then the barrel cutter is used to quickly cover the surface. It is interesting that the eyeball plays tricks with the brain. The image of large step-overs suggests to the brain of a large cusp height. But running your fingers on the surface demonstrates a near-perfect surface.
Metal Laser Sintering Hybrid Milling
This metal laser sintering hybrid milling process combines metal powder 3D laser sintering with high speed milling finishing into one machining system. This process is similar to 3D printing, but using any one of several different grades of powdered metal with laser sintering to create a 3D part in metal. The system lays down a thin layer of powder, laser sinters that level in accordance to a 3D solid model, repeats that process for ten layers and then switches to a high speed mill and finish machines the ten layer stack which equals .020" thickness. It then continues the process until the complete part is finished. The laser sintering process can be controlled to create solid as well as porous sections throughout the process so the porous areas can then be used as venting areas in injection molds or medical/dental implant type parts.
Circle Segment Tools and Toolpaths in Action
Check out this finishing pass comparison between the support of a circle segment oval form cutting tool within automated CAM finish toolpaths and a ball end mill on a blade. The comparison shows a 77-percent cycle time reduction due to a much larger stepdown and fewer finish passes. When machining P20 tool steel (3Cr2Mo/1.2311), surface finish is actually improved.
A new diamond-coated end mill "cutting" carbide. Historically carbide molds, dies and components were formed using EDM or grinding. This series brings all the benefits of direct milling to forming complex 3D shapes from CAM data. A patented, highly advanced and durable diamond coating gives the specially designed ball end mill the capability to "cut" small micro chips of carbide as it forms the programmed feature. This video shows a 1.00mm ball end mill taking just 39 minutes to create a complex Hexalobular shape on VF-20 super micro grain carbide, rated at 92.5Hra. Roughed and finished with just one tool, from start to finish, leaving a clean, burr free surface finish.
Surface finish problems can be profit killers in the moldmaking shop. One of the most common causes is chatter created by vibration in the CNC machine tool cutting process. This can lead to higher costs, delayed deliveries and even lost orders due to poor quality. In addition, vibration can cause uneven tool wear, resulting in poor surface finish, geometry inconsistencies and reduced tool life.
Chatter is caused by the inherent natural frequency of the cutting tool. It can be triggered by many process conditions: toolholding, cutter tooling, part fixturing and machine conditions. Typically operators try to combat chatter by combining multiple solutions, but some of these may impossible to implement due to part geometries or machine limitations. Fortunately, there is new technology available today that can eliminate chatter from your cutting processes.
Mold Making: Your Road To Success
Mold Making - Your Road To Success is an educational video targeted at youth who are considering their career choices. It introduces numerous people in mold manufacturing who talk about the opportunities, their careers, responsibilities, rewards and the fulfillment their jobs provide.