Milling in Slow Motion
Rough milling operations can take hours on large components and typically remove more than half the raw material by volume. Selecting the proper machining method for the component and machine tool creates a successful and stable system. The use of plunge roughing, commonly referred to as plunge milling, has grown recently as cutting tools that can handle the tough requirements of this machining method have become more readily available.
Whether using a drill or milling tool, the toolholder is just as important. Tool stability is critical to eliminate deflection that can cause tool failure during plunging. Milling tools have a larger body with a large core that is very stable and can be mounted solidly to a spindle adapter. A good rule of thumb is to avoid using a tool that is larger than the diameter of the spindle taper at the spindle nose
Correct alignment lock selection will reduce maintenance costs, molding downtime and increase part quality over the mold’s entire life.
Understanding the effects of injection on the core, slide and associated components is critical to selecting the best side-action methods for a given application. This first of two articles will discuss the basic physics underlying all side-actions.
Both copper and graphite provide approximately the same end result, so it is important for a shop to consider the advantages and disadvantages of each material in order to discover what would work best in their shopfloor environment.