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
Prototyping helps evaluate and test a design, clarify production costs, sell a product and secure patents.
While both hot runner and cold runner systems have their benefits, for design flexibility as well as reduced cycle times and costs, hot runner systems will probably be the better choice.
How-to, step-by-step instructions that take you from making the master pattern to making the mold and casting the plastic parts.