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Die high-speed milling technology
High-speed machining has become a critical technology in modern mold manufacturing, driven by the increasing complexity of plastic parts and the demand for intricate mold designs. As the need for more detailed and aesthetically appealing products rises, molds have evolved to include more freeform curved surfaces, leading to more complex structures. This evolution demands advanced processing technologies that not only ensure high precision and surface quality but also enhance the visual appeal of the final product.
With continuous advancements in high-speed machining technology—such as improvements in CNC systems, machine tools, tooling, and CAD/CAM software—the industry has witnessed a significant transformation. High-speed cutting offers substantial benefits over traditional methods, including increased metal removal rates, reduced cutting forces, and minimized heat generation. These advantages lead to shorter machining times, improved efficiency, and better surface finishes. Additionally, high-speed machining reduces the need for post-processing steps like grinding and polishing, which saves time and costs while maintaining high-quality standards.
One of the key components of high-speed machining is the development of specialized machine tools. These machines are designed with high dynamic and static stiffness, thermal stability, and optimal damping characteristics. The use of advanced materials such as high-quality cast iron and polymer concrete helps improve vibration resistance and thermal stability. Moreover, spindle design plays a crucial role, with high-speed spindles utilizing hydrostatic or aerostatic bearings to achieve precise and stable operation at extremely high speeds.
The drive system of high-speed machines must support rapid feed rates and accelerations, often using linear motors to eliminate inertia and improve response times. Modern CNC systems are equipped with features like high-speed digital control loops, feed-forward control, and advanced interpolation methods to ensure smooth and accurate machining. These systems also incorporate error compensation functions to maintain precision under varying conditions.
Cooling and lubrication are essential in high-speed machining, where dry cutting methods using oil/gas lubrication are increasingly preferred. This approach effectively removes heat from the cutting zone and extends tool life while improving surface finish. Tool holders and cutting tools are also specially designed to handle the high centrifugal forces and vibrations associated with high-speed operations, ensuring stability and accuracy.
In terms of machining strategies, high-speed processing involves roughing, semi-finishing, and finishing stages, each with specific techniques to optimize efficiency and quality. Advanced CAM software plays a vital role in generating efficient toolpaths that minimize tool wear and maximize productivity. Programming for high-speed machining requires careful planning to ensure safety, smooth tool movement, and uniform tool load distribution.
Overall, high-speed machining represents a major advancement in mold manufacturing, offering faster, more precise, and more cost-effective solutions. While its adoption in China is still developing, its potential to revolutionize the industry is undeniable. As technology continues to evolve, high-speed machining will remain a cornerstone of modern manufacturing.