High-Speed Die/Mold Machine Fights Heat, Vibration
IMTS 2018: Hwacheon’s Sirius UL+ vertical die and mold machining center features a 20,000-rpm, built-in motor spindle that provides high-speed cutting.
Hwacheon’s Sirius UL+ vertical die and mold machining center features a 20,000-rpm, built-in motor spindle that provides high-speed cutting; a table size of 47.24" × 23.62"; and a travel range of 41.34" × 23.62" × 21.65" in the X, Y and Z axes, respectively.
The machine frame, a rigid bilateral gate structure, supports the X-axis drive. It diverts load, vibration and heat from the upper section of the machine. These features help to keep the feed drive stable after hours of operation. The short distance between the X-axis drive and the tool’s point of contact helps to maintain rigidity and machine precision.
The spindle uses the company’s oil-jet lubrication technology. The lubrication system injects a jet of oil directly onto the spindle bearing for effective cooling. The motor and spindle assembly are jacket-cooled to limit displacement caused by heat.
Software components monitor variables related to work environment and machining conditions to improve efficiency and thermal accuracy. Tool Load Detect provides real-time measurement of tool load. High-Efficiency Contour Control, a user-friendly programming interface, offers custom contour control. Cutting Feed Optimization uses an adaptive control method to regulate feed rates in real time. Frame Displacement Control uses thermal sensors to monitor and correct thermal displacement. Spindle Displacement Control monitors temperature at a number of points within the spindle assembly and predicts thermal displacement. Thermal Displacement Control integrates Spindle Displacement Control and Frame Displacement Control.
Milling complex forms in hardened tool steel involves more than just fast, light cuts, says this maker of medical-related injection molds. Here are some of the ingredients of an effective hard milling process.
The recipe for best results is simple: Start with a rigid machine, add a high pressure through-the-spindle coolant system, then combine these with the right drill geometry plus the right speeds and feeds.
While aluminum molds are commonly used to create prototypes or to serve as stopgap bridge tooling, they are starting to receive greater attention for production work. This shop’s approach to creating aluminum molds in one day to three weeks is the same for each of these situations.