D e s i g N / b u i l D / r e pA i r MAY 2013
Exhibitor Product Showcase, PG. 50
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Successful, Proftable Mold Design PG 34. FEATURES
Conquering the Quoting Challenge PG 41. Enhance Mold Precision By Going Five-Axis PG 44. Taking Mold Repair to the Next Level PG 48. VoluMe 16 / NuMber 5
performance is key.
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Richard G. Kline, CBC | President Melissa Kline Skavlem | COO Richard G. Kline, Jr. | Group Publisher Tom Beard | Senior V.P., Content Steve Kline, Jr. | Director of Market Intelligence Ernest C. Brubaker | Treasurer William Caldwell | Advertising Manager Ross Jacobs | Circulation Director Jason Fisher | Director of Information Services Kate Hand | Senior Managing Editor Jeff Norgord | Creative Director Rhonda Weaver | Creative Department Manager Dave Necessary | Senior Marketing Manager Allison Kline Miller | Senior Event Manager ALSO PUBLISHER OF • Modern Machine Shop • Products Finishing • Plastics Technology / PT Handbook • Production Machining • High-Performance Composites
• IMTS Directory of Exhibits • Products Finishing Directory • NPE Offcial Show Directory • Automotive Design & Production • Composites Technology
MoldMaking Technology magazine (ISSN #1098-3198) is published monthly by Gardner Business Media, Inc., 6915 Valley Avenue, Cincinnati, Ohio 45244. 800-950-8020, 513-527-8800, Fax: 513-527-8801, gardnerweb.com. Canadian Agreement #40012278. Nonqualifed subscription rates per year are $89.00 in the United States, $99.00 in Canada and Mexico. All other countries are $200.00 per year, payable in U.S. funds. Single copies $10.00 per issue in the United States and Canada. CANAdA POST: Canada Returns to be sent to Bleuchip International, P.O. Box 25542, London, ON N6C 6B2. Publications Mail Agreement #40612608. POSTMASTER: Send address changes to: MoldMaking Technology magazine, Gardner Business Media, Inc., 6915 Valley Avenue, Cincinnati, Ohio 45244. ©Entire contents copyright 2013. No portion of this publication may be reproduced in any form without written permission from the publisher. Views expressed by the bylined contributors should not be construed as a reflection of the opinion of this publication. Publication of product/service information should not be deemed as a recommendation by the publisher. Editorial contributions are accepted from the moldmaking industry. Contact the editor for details. Product/service information should be submitted in accordance with guidelines available from the editor. Change of address: Send old label as well as new address to Circulation, MoldMaking Technology magazine, Gardner Business Media, Inc., 6915 Valley Avenue, Cincinnati, Ohio 45244. Periodicals postage at Cincinnati, Ohio and at additional mailing offices. PRINTED IN THE U.S.A.
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Contents
May 2013 Volume 16 / Number 5
18
41
Features
50
Departments
34 Software Successful, Proftable Mold Design What to consider when searching for an all-in-one mold design solution. 38 Software Ramping Up to Five-Axis Programming Steps for making the transition from three- to five-axis machining. 41 Software Conquering the Quoting Challenge Adding the right multi-CAD viewer to your quoting process helps improve customer communication, secure new business, and save time and money. 44 Machining Enhance Mold Precision by Going Five-Axis Here’s how to manufacture large or high-precision, complex molds while maintaining efficiency. 48 Mold Maintenance/Repair In the Trenches: Taking Mold Repair to the Next Level Improving mold repair efforts—whether you’re on the bench or managing—is not only a worthy goal, but also holds its own reward. 50 amerimold Exhibitor Product Showcase Highlights of some of the technology on display at next month’s amerimold Expo in Rosemont, IL, June 12-13.
6
From the Editor: MoldMaking Technology Live!
6
What’s New on MMT Online: amerimold expo
8
New Business Opportunities: Market Diversifcation
10
Your Business: Three Ways to Eliminate Waste
12
MoldMaking Business Index
14
Profile: Buss Precision Mold
18
Case Study: Mold Materials
24
Case Study: Training
28
Case Study: Software
61
Product Focus: Eastec
69
MoldMaking Marketplace
70
End Market Report: Automotive and Consumer
71
Ad Index
72
TIP: Software
ON ThE COvER Image courtesy of Vero Software (Wixom, MI). Rendered image of a 16-cavity mold insert for the trigger of a household cleaning spray. 3D mold tool was designed by Alliance Tooling who switched to VISI Electrode and reduced design time by 80 percent. Images courtesy of (left to right) JMMS, Kubotek USA and Bales Mold Service.
5
TRICKS OF THE TRADE vIDEO ACCESS
Great Tips from This Issue
1. Shopping List. When shopping for the right design software, keep in mind universal fle types, part changes, fow analysis, map keys, libraries, quick and seamless translation to the shop foor and availability in one software package.
2. It’s All in the Training
3. Quote Me on That
4. Made for Moldmaking
Though using a CAM-integrated solution helps ease the transition from 3- to 5-axis, the true power and versatility of 5-axis programming can only be found with software training.
The right multi-CAD viewer can improve your response to the initial quote request. One reason is that you can actually quote the prospective customer.
Mold manufacturing demands high-performance machining. Period. Machine tools need to be highly engineered pieces of equipment designed with the capabilities to meet these performance standards.
Page 38.
Page 34.
4 MoldMaking Technology May 2013
Page 41.
Page 44.
5. Analyze This Simulation can analyze different variables of the design of a new mold. After determining the desired geometry, the process starts with the selection of the injection point or gate type. Page 72.
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From the Editor
MoldMaking Technology Live!
This MonTh on moldmakingtechnology.com
Come experience it at amerimold Expo 2013, June 12 - 13 in Rosemont, IL.
MMT Zone: amerimold expo
To put it simply: this year we have a lot of good stuff going on for you to see, hear, experience and enjoy. We are back in the Chicago area and co-locating with a few other industry events. Our exhibit hall is full of machine tool, cutting tool, material, software, components, repair, finishing and additive technologies, services and expertise specific to your mold building and processing needs. We are bringing back our Networking Party and MMT’s “Top 10 Reasons to be a Moldmaker” t-shirts. We are celebrating our annual Leadtime Leader Award winners and we are honoring other industry veterans this year as well. We have developed a technical conference following the magazine’s format with participation from leading mold manufacturers and molders, and new this year we are debuting show floor technology/strategy presentations called Knowledge Centers (a peek at the technology to be on display at the event begins on page 50). A great menu of opportunities! The technical conference is broken down into three blocks: ENGINEER Block Sponsored by Society of Plastics Engineers, Mold Making and Mold Design Division whose goal is to bring to the forefront the technologies and best practices necessary for the critical decision-making that needs to take place by the mold buyer and mold builder. Mold Shop Senior Management, Mold Procurement Personnel, Mold Designers, Part Design, as well as processing and troubleshooting personnel should attend. BUILD Block Sponsored by Tooling and Manufacturing Association (TMA) whose goal is to provide examples, analysis and discussion that provokes decision-makers to plan for how their shop and staff will look in the year 2015. Company Owners, Operations/Plant Managers, Shop Foremen and HR Managers should attend. MAINTAIN Block Sponsored by ToolingDocs whose goal is to develop awareness and planning for more proactive mold maintenance by molders and their mold builders. Toolroom Managers at Molding facilities, Molding Facility Owners and Plant Managers, OEM contacts responsible for tooling productivity and costs, and personnel at mold building companies responsible for repairing and maintaining their customers’ tools should attend.
REGIsTER ToDAy!
amerimoldexpo.com amerimold is a trade show, technical conference and networking event that connects mold manufacturing and plastic injection molding. The amerimold trade show floor features exhibitors displaying products used for designing, building, maintaining, repairing and processing molds. Products on display include: machine tools, cutting tools, CAD/CAM, 3D printers, materials, mold/die/tool services, mold components, and more.
DaTes & TiMes Conference & exhibition: • Wednesday, June 12th: 9:00 am – 5:00 pm • Thursday, June 13th: 9:00 am – 3:00 pm Registration: • Wednesday, June 12th: 7:30 am – 5:00 pm • Thursday, June 13th: 8:00 am – 3:00 pm
Venue Donald E. Stephens Center 5555 N. River Road Rosemont, IL, 60018
amerimold 2013 Technical Conference PRogRaM ENGINEER, BUILD, MAINTAIN
Presented by MoldMaking Technology magazine, the amerimold technical conference delivers expert insights into the production and management challenges facing mold manufacturers and molders. • View the ENGINEER program • View the BUILD program • View the MAINTAIN program
neTwoRking oPPoRTuniTies The annual Leadtime Leader Awards, amerimold cocktail reception and new Knowledge Centers connect exhibitors and attendees for social and technical networking.
show FlooR PResenTaTions View the KNOWLEDGE CENTER schedule.
Co-loCaTing PaRTneRs • OMTEC – orthopedic manufacturing and technology • SUR/FIN – surface finishing, surface engineering, surface coating, electroplating and precision engineering • Fastener Tech – fastener manufacturers, suppliers, distributors and users
Browse
Christina M. Fuges Editorial Director
Follow MMT on:
6 MoldMaking Technology May 2013
Follow @ MMTMag
• Hotel/Travel • Search Exhibitors • View Floor Plan • Education & Events • About Our Experts • Contact Us
New Business Opportunities
By Sherry L. Baranek Like many mold manufacturers, Midwest Mold Services, Inc. (Roseville, MI)—a full service plastic injection mold building company and supplier of low-volume plastic parts—never had to seek out customers. Instead, the company had customers seek out their expertise and business was booming. However, challenges in the past several years, namely foreign competition, has resulted in moldmakers like Midwest Mold needing to learn how to be proactive with its marketing efforts. Midwest Mold President and CEO John Hill reached out to the Michigan Manufacturing Technology Center (MMTC) for assistance. As a result, Midwest Mold was one of the first companies to go through MMTC’s Market Diversification program, in which the MMTC analyzes a company’s challenges and delivers a series of outputs and benefits addressed on a company’s individual “The educational training, needs. “The MMTC educated us in the industries we were resources and system considering as a customer of prospecting for new base (medical, electronics, accounts were the most defense, and appliance) and helped us narrow it down,” valuable benefts that Hill notes. “Pursuing certain came from working with markets would require addithe Michigan Manufactur- tional investment in tooling or machinery; we went for the ing Technology Center.” low hanging fruit first.” Midwest Mold also invested in a new website from MMTC. Over the next 18 months, the website brought in opportunities to bid and secured roughly $800,000 in new business in the appliance and recreational vehicle markets. Hill says that before getting with the MMTC, he viewed their web presence as an online brochure and not much else. Now, however, he recognizes the benefit a properly built website brings by serving as a sales tool that isn’t limited by geography. The optimized website is currently bringing in eight to 10 qualified leads a month and all inquiries end up in Hill’s inbox where he sorts through them and responds personally to the qualified leads. Using its custom cost model Midwest Mold can accurately quote jobs to be sure that there is profit involved. However, Hill notes that “quoting is not free; quoting costs you money every time. “We are currently doing a refresh to our site, which is mostly directed at content management,” Hill says. “However, a refresh with updates as to our capacity, equipment and services is also being incorporated,” he elaborates. “The new site
8 MoldMaking Technology May 2013
Photo courtesy of Midwest Mold Services, Inc.
Think Big to Narrow Down Your True Markets
Midwest Mold President John Hill used the Michigan Manufacturing Technology Center’s Market Diversifcation Program, which was tailored to his business, and resulted in $800,000 in new business opportunities.
has also consolidated our main and micro sites, is more mobilefriendly, includes case studies and is a better balance for us with inbound and outbound lead generation.” Seven years ago, 100 percent of Midwest Mold’s business was in the automotive industry; today, it is approximately 78 percent automotive. “The educational training, resources and system of prospecting for new accounts were the most valuable things that came from working with MMTC,” Hill concludes. “These were most helpful—not just for the diversification aspect—but for the core business as well. The investment in website optimization proved itself through actual awarded revenue.”
For more iNFormaTioN: Midwest Mold Services, Inc. / (586) 855-0560
[email protected] / midwestmold.com MMTC / (888) 414-6682 /
[email protected] / mmtc.org
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Your Business
three Ways to Cut Waste in Your Shop By Thomas R. Cutler Most moldmakers dream of capturing a 20-percent increase in output—even better if it is achieved in a few months. Moldmaking is a knowledge work environment, where projects are frequently in process, with more assignments on the way. Among all industrial sectors, standard industrial classifications (SIC) by the Department of Labor suggest that customers of moldmakers demand the most in scheduling, accuracy and project completion speed. Here are three recommendations for cutting the waste and giving your customers what they want. 1. Get Lean Moldmakers must improve project management processes to dramatically increase output and productivity. A new option for the moldmaking industry, according to Mark Woeppel of Pinnacle Strategies—a consulting firm focused on operations management—is RABIT (rapid analysis and bottleneck improvement team), which like Six Sigma, Theory of Constraints and Lean Manufacturing, can impact Waste can be eliminated task engagement, when moldmakers use lean resource increasing productivity. best-practice processes, This is achieved with proaclean inventory control solu- tive scheduling by implementing a single, rational tions, and hiring the right task priority management staff the frst time. system as well as performance management via clear feedback on process performance. Focusing on the bottleneck processes and implementing only the changes that will have the largest impact, are typical elements of a RABIT project. Moldmakers must eliminate over-production, coordinate work scheduling and prioritization, and prevent resource multitasking. 2. Control Inventory More than half of all moldmakers employ fewer than 50 workers and have yet to implement any sort of lean programming. For this large majority in the industry, cost-savings are best found in inventory control and management. Fishbowl Inventory—a popular inventory management solution among QuickBooks users—says, “As small-to-medium moldmakers grow and face increasing competition, the need for affordably priced inventory management is identical to larger moldmaking organizations. With automatic work orders, multilevel bills of materials, and other advanced tools, moldmakers must streamline complex tasks and speed up production lines.”
10 MoldMaking Technology May 2013
3. Hire the Right Staff Nowhere in moldmaking is waste more evident than when hiring the wrong personnel. Stephen Berry from Scientific Management Techniques—a provider of manufacturing skills assessments—says, “It is quite easy to predict employee success in a mold shop. Hands-on assessment machines identify and measure the skills required to operate, maintain and troubleshoot a modern moldmaking facility.” Portable manufacturing skills assessments deliver a scientific-based, data-driven workforce skill assessment solution that lowers the risk and cost of hiring. It also drives industrial performance by increasing the skill level of the workforce. The data-driven hiring process allows moldmakers to hire workers based on proven, validated success factors and extend lean initiatives into the hiring process. Identifying and measuring skills prior to hire is the single most effective means to ensure quality, highly productive personnel in manufacturing. Waste can be eliminated when moldmakers use lean best-practice processes, lean inventory control solutions, and hiring the right staff the first time. ConTRiBuToR
Thomas R. Cutler is a manufacturing journalist and President/CEO of TR Cutler, Inc. (trcutlerinc.com).
FoR moRe InFoRmatIon: Pinnacle Strategies / pinnacle-strategies.com Fishbowl inventory / fshbowlinventory.com Scientifc Management Techniques / scientifc-management.com
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MoldMaking Business Index
Total Index for March 2013: 51.5 Direction
Rate
-1.1
Growing
Slower
3
54.1
-2.2
Growing
Slower
3
45.2
46.3
-1.1
Contracting
Faster
12
54.8
52.9
1.9
Growing
Faster
3
48
47.7
0.3
Contracting
Slower
10
Supplier Deliveries
56.5
53.3
3.2
Lengthening
More
4
Material Prices
67.9
73.9
-6
Increasing
Less
16
Prices Received
49.4
52.9
-3.5
Decreasing
From Increasing
1
Future Business Expectations
68.4
69.2
-0.8
Improving
Less
16
MoldMaking Business Index
51.5
51.3
0.2
Growing
Faster
1
12 MoldMaking Technology May 2013
MoldMaking Business Index 60
55
50
45
13
13 3/
2/
2 13 1/
/1
12
2
2 /1
11
12
/1 10
9/
2
12
8/
12
7/ 1
12
40
6/
For the second month in a row, our survey of the North American moldmaking industry indicates that overall activity levels increased in March. The MoldMaking Business Index for March 2013 is 51.5. The latest index value is a 0.2-point increase from the February value of 51.3, but it is a 4.6-point decrease from the 56.1 value posted in March 2012. A moderate rise was reported in the New Orders category for the third consecutive month, and the Production category also registered a third straight monthly increase. Supply conditions, as measured by the Supplier Delivery Times and Materials Prices components, were once again the most notable negative factors in the index this month. Supplier delivery times continue to get longer, and materials prices have increased for 16 months in a row. Prices Received were steady-to-lower. Future Expectations changed very little and remain optimistic. The New Orders component came in at 52.6 in the latest month. The domestic manufacturing sector lost a little momentum in March, but the overall uptrend remains intact for now. This month’s gain in new orders was not strong enough to expand the industry’s Backlogs in March. The Backlog sub-index slipped to 45.2 for the month. The Production sub-index of 51.9 indicates that work levels held steady when compared with the previous month. The Employment component is 54.8, which means that payrolls were higher for the third straight month. The prices received in the moldmaking sector weakened a bit in March. The Prices Received sub-index for March is 49.4. This ended a two-month streak of moderately rising prices received. The upward momentum in the sub-index for Materials Prices eased back this month to 67.9. So materials prices are still
12
Exports
5/
Employment
4/
Backlog
12
51.9
12
Production
3/
53.7
going higher, just not quite as rapidly as they jumped up in the previous month. Supplier Delivery Times are getting longer, and this component escalated to 56.5 in March. Offshore orders extended their downward trend last month, but the pace of decline remains moderate. The Exports sub-index is 48.0. This Index is based on a monthly survey of subscribers to MoldMaking Technology. Using the data from this survey, Gardner Research calculates a diffusion index based on 50.0. A value above 50.0 indicates that business activity expanded when compared with the previous month, and a value below 50.0 means that business levels declined.
Trend
2/
52.6
1
New Orders
/1
Change
12
February
1/
March
12
Sub-Indices
Our MoldMaking Business Index hovered just above the breakeven 50-line through most of the frst quarter. This is a refection of the gradual pace of growth that the overall U.S. economy experienced in the frst quarter. For the past 3 1/2 years, GDP in the U.S. has expanded at a rate of just about 2 percent. It is expected that this pace will continue through the frst half of 2013 before accelerating gradually in the second half of this year. The economy’s fundamentals are poised for accelerating economic growth, but it will take another quarter or so for U.S. households to adjust to the higher payroll taxes that went into effect this year. And U.S. businesses will need this time to adjust to the effects of the diminished government spending resulting from the sequestration. The most serious effects of these two factors will be behind us later this year, and economic growth will escalate noticeably as we head for 2014.
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By Sherry L. Baranek Buss Precision Mold Inc. (BPM; Clackamas, OR) is a 10-employee mold manufacturer that takes pride in the fact that while the shop may be small in numbers, it possesses the technology and capacity of a large shop with a specialty in collapsible core, unscrewing and overmolding tools and complex action requirement designs. Serving industries like medical, aerospace, military/ITAR, industrial, electronics, transportation, consumer and irrigation/ agriculture, the company’s average leadtime on a project is six weeks, which company president Jonathan Buss says is a result of “extreme” customer service and the company mantra, “We do what we say we will do!” In 1988, Buss and his father Earl founded the company together after both worked for another moldmaker for a number of years and wanted to break out on their own. Buss recalls that his father taught him everything he knows. “A lot of people tell me they could never work with their father, but working with him was a privilege,” he notes. The duo started in Earl’s garage shop, taking on overflow work from the company they left on good terms, and gradually gained more customers based on Earls’ reputation around the area as the “go-to” guy for complicated projects. Soon after, they obtained their first CNC machine and offline computer programming system for use in manufacturing the
Peter Wiessner CNC Moldmaker is probing in two-cavity blocks to run on the Makino V56.
14 MoldMaking Technology May 2013
Photos courtesy of Buss Precision Mold Inc.
Getting to the “Core” Of Buss Precision Mold’s Success
Mold Designer Trent Paulsen with a 3D mold design of an eight-cavity, SPI Class 102 mold using TopMold from Missler Software.
molds. They continued to obtain more and more CNC equipment keeping up with technology and slowly added CNC EDM and CNC wire EDM over time. Core Competencies In 2000, BPM obtained its first high-speed milling machine, a Roeders RFM-600. With its 42,000-rpm spindle and 1,200-ipm feedrate the company could see the immediate benefit before the training was even complete. “After training a couple of days, we ran an EDM electrode that would have taken approximately 30 hours to run (if everything went right!) on the conventional equipment,” Buss notes. “It took fewer than three hours to run and it required almost no hand work to finish. The previous method would have required hours of hand work and wouldn’t have attained the same accuracy either. This was confirmation the large investment for a small shop was worthwhile.” Since then, Buss notes that high speed and hard milling have evolved into core competencies of BPM. “When EDM is necessary, using the CNC EDM in conjunction with lights-out machining are key components of staying competitive and providing precise tools with compressed leadtimes,” he comments. The latest additions of machinery are a DMG DMC 105 linear motor high-speed milling machine, a dual-pallet Makino V56, and the latest Mitsubishi EA12 advanced CNC sinker EDM. “The increased accuracies and better surface finishes are some of the greatest benefits realized from the new equipment,” Buss comments. Core Values BPM also relies on a set of core values to accompany its core competency focus. According to Buss, the company treats all of its employees with dignity and respect—and they work as a team to accomplish all tasks. “We personally set goals to continually strive to maximize productivity,” Buss emphasizes. “We take responsibility for our decisions and actions in our quest to produce the highest quality work we can be proud of.”
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Core Strategies BPM is focused on increasing its customer base in the medical product category and creating more brand awareness in order to ensure long-term success by keeping its current equipment running as many hours as possible. “Our brand awareness is well established with OEMs and custom molders who use our tools,” he elaborates. “They often discuss how they like to work with and run BPM tools due to making good parts the first time, being on schedule, and tool maintenance being easy to facilitate due to well thought-out designs. The main focus on creating more brand awareness is getting the tools on to new OEMs and molders’ floors where they speak for themselves.” To that end, BPM is planning to increase capacities. “We are currently looking into a larger capacity horizontal milling machine and some five-axis machines as future equipment purchases,” Buss concludes. “We will continue to exhibit small company nimbleness to quickly adapt to our customers’ needs, while having the technology and capacity of a larger shop.”
For more inFormation: Buss Precision Mold Inc. (503) 652-5804
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Case Study / Mold Materials
By Rich Martin A few years ago, executives from Honda North America called a group of Tier One suppliers together and shared some aggressive numbers. Based on Honda’s new production requirements, the Honda execs wanted these suppliers, who provided assemblies with injection-molded parts, to commit to increased productivity and much shorter cycle times. Honda instructed these Tier One vendors to meet these new production numbers by replacing traditional P20 tool steel in their injection molds with a material offering better thermal transfer and shorter cycle times. Their forecast, in short, called for aluminum. The Aluminum Trend The trend in moldmaking today is to build with aluminum and it certainly offers clear-cut advantages over P20 for lowvolume production and prototyping. Aluminum adds more thermal capability, but it’s not robust—a key concern, as the suppliers would be using these injection molds for a range of high-volume parts. From Honda’s point of view, aluminum offered benefits in addition to faster thermal transfer and shorter cycle times, including better machinability and faster tooling development and production. The toolmakers would need to meet Honda’s objectives, while also delivering the durability and maintenance specs the Tier One suppliers were looking for. An internal Honda team worked with Alcoa and introduced them to the Tier One suppliers, saying, “Alcoa is your partner. They know the materials.” As Honda’s global seating supplier, TS Tech participated in these meetings and discussions. Steve Furniss, Department Manager of TS Tech North America’s Tooling Administration, would be the man driving TS Tech’s switch to aluminum tooling. By his own admission, Steve had limited experience with tooling made with aluminum, but he did his homework. He attended the last two amerimold expos and had extensive discussions with Alcoa about QC10, a tool-grade alloy that’s harder than most aluminum alloys. The cycle time reductions
18 MoldMaking Technology May 2013
Images courtesy of JMMS Inc.
The Forecast Called For Aluminum
Fixed inserts on the core side of a thermoplastic injection mold made with MoldMax for localized cooling. (Note: all images show a new hybrid tool currently in development at JMMS.)
Another fxed insert for the core side, made with MoldMax to ensure localized cooling for deep ribs.
available with QC10 were impressive, so with his material supplier set, he drew up his short list of toolmakers. Ideally, these toolmakers would understand the production characteristics and maintenance requirements of QC10, and how they differ from those of P20. Aluminum Experience That’s where we came in—we meaning JMMS, a second-generation tooling manufacturer headquartered in Easley, SC. We were one of three tooling suppliers TS Tech ultimately selected to build five injection molds with aluminum. When Steve was sourcing the tools and talking to toolmakers, he was clearly looking for total program management—engineering and manufacturing, consultation during maturation and optimization, and maintenance. We do all of that and as an added benefit, we brought extensive aluminum tooling experience to the table, having built
Case Study / Mold Materials
tools with aluminum for customers in other industries. David M. Bowers II, JMMS CEO, Brian Rossi, our Program Manager, and I participated in a conference call with Honda, TS Tech and the other toolmakers. The challenge, from our point of view, would be to comply with Honda’s material mandate while meeting TS Tech’s requirements for part quality and mold durability. The Project: Hybrid Tooling We had detailed early-stage discussions with Steve about aluminum tooling. Eventually, we proposed hybrid tooling instead. Hybrid tooling is a robust solution that combines aluminum with P20 and MoldMax, a copper beryllium alloy that’s much denser than traditional tool steels. Hybrid tooling is more costly than aluminum tooling, but the engineering pays off with shorter cycle times, better dimensional control and improved corrosion resistance. Each material plays a designated role designed to capitalize on its strengths. The aluminum content in the hybrid tool’s design would comply with the Honda mandate, which was another point in its favor, but we also planned to use P20 for better mold durability and ease of maintenance. In addition to the increased productivity and material selection Honda wanted, Steve was looking
Lifter made with MoldMax for localized cooling on deep bosses.
for a new thermoplastic injection mold to deliver one million shots, five years in mass production and five more years of service life. Upfront Collaboration We made multiple visits to TS Tech to meet with Steve and his production and plant engineers, discussing the parts, injection molding and the plant’s maintenance process, so we were comfortable with the specs and warranty requirements. The hybrid tools we planned to build for TS Tech would use engi-
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neering we had tested and proven with thermoplastic injection molds for other industries. Hybrid tooling combines materials for specific performance and production characteristics, while also minimizing each alloy’s individual weaknesses. In addition to Alcoa’s QC10 aluminum, we spec’d MoldMax for the shut-offs because of its hardness (in addition, the two percent beryllium content in MoldMax would offer better thermal conductivity). We planned to build TS Tech’s new tools with a P20 support system for durability and add QC10 for thermal conductivity. The QC10 inserts would provide conformal cooling, but as so often happens in engineering, solving one problem created another. You have to be careful clamping on aluminum because it will wear, so we developed a solution that backed the QC10 inserts with P20, installing zero pads to protect the parting line. Engineering David and Brian drove the engineering from start to finish, focusing on our key objectives—aluminum content and shorter cycle times for Honda, plus the part quality and tool durability TS Tech wanted (which meant no increase in preventive maintenance requirements compared to P20 tools).
The cavity-side mold base, made with P20 for durability.
Our engineers stayed in constant contact with Steve and TS Tech during the mold design phase, reviewing the drawings and also discussing part design (we always look for part design enhancements, reducing heavy wall sections to decrease material usage and part weight). TS Tech had specific requirements for material flow, the parting line, gate location and ejector marks, so we had to factor these into the engineering. We also look for tool design opportunities and we found them here, extending the tool life by correcting problems with the parting line and not having enough draft on the shut-offs.
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Case Study / Mold Materials
Tryout and Optimization We had mold tryouts in December 2011 and January 2012 followed by two rounds of data review and optimization. Brian Rossi’s a veteran toolmaker and he made key suggestions during maturation that Steve approved—spacing the waterlines differently than on standard P20 tools, for example, and changing the shut-off angles to reduce wear. Once we’ve made our preliminary decisions, the tool is 90% ready, so optimization is our last chance to add to the tool’s integrity. JMMS also suggested some minor changes on part design, to ensure cleaner ejection and better dimensional control. Following tryouts and optimization in South Carolina, we sent the tool to Ohio to go through PPAP. The mold performed well—too well, as it turned out. The hybrid tool’s reduced cycle time meant it was exceeding the capabilities of the molding machine, “pushing the bottleneck somewhere else,” as David Bowers explains. “Our solution made screw speed adjustments to realign the mold with the production process.” Monitoring and Meeting Objectives We started building our first tool during Fall 2011 and delivered it in February 2012. We’re now in the monitoring phase
22 MoldMaking Technology May 2013
Core insert showing lifter pockets.
with Steve and his colleagues. At this point, we can say that we’ve met our customer’s objectives (and their customer’s too). The new thermoplastic injection mold has provided the improved thermal capability and shorter cycle times required for increased capacity. We haven’t seen any maintenance or warranty issues, which I credit to solid engineering, highlevel build quality and of course, a more experienced approach to material selection.
TS Tech’s molding subsidiary maintains the mold and we stay in close contact to make sure cycle times, material usage and part quality remain in control. JMMS is currently in discussions with TS Tech on a hybrid tooling program for textured surface parts, which we’re looking forward to starting. Lessons Learned So what are the lessons learned? From our point of view, OEMs and Tier One vendors need to work with tooling companies who can add value with experienced, proven engineering. Aluminum is certainly a valuable material for mold manufacturing, but in the end, you’re investing in a process—one engineered to deliver a specified set of performance and production characteristics. It’s easy enough to build tools with aluminum for faster production and increased capacity, but these gains have to be weighed against the tool’s durability and maintenance requirements. Saving money with a lower cost tool that requires excessive or unplanned maintenance and repairs, or that fails before the end of the program isn’t going to work in the long run. Our goal, ultimately, is to do more than make and sell tooling. We’re looking for long-term customer relationships, where our total program management and our engineers can add value at every point in the process. We want to work with customers who can tell us what they want, but are wise
enough to know that good tooling engineers will go beyond that to give them what they need. When the customer and toolmaker both approach tooling as a strategic investment in quality, and both recognize that tooling engineering adds significant value, then you wind up with innovations like hybrid tooling. And these innovations deliver the return on investment you want—along with a sunny long-range forecast.
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Case Study / Training
By Sherry L. Baranek Thogus (Avon Lake, OH)—a 62-year-old custom injection molding company that serves the healthcare, aerospace, small household appliances, consumer, industrial, telecommunications and plumbing markets—recently partnered with Erie, PA-based Beaumont Technologies Inc. to send nine of its employees to the “Mold Design for Project Engineers Course” to learn about key plastic principles, including plastic flow, types of melt delivery systems, how to size up a mold for a given molding machine, mold cooling design strategies, and common mold design pitfalls, among other topics. Thogus President Matt Hlavin is a proponent of creating partnerships with everyone who touches the company’s supply chain. “We are not just your ship and shoot molder,” Hlavin notes. “We have the expertise and technology to work with our clients from product development to prototyping all the way through production. Being engaged in the forefront of change is critical for our success. In doing so, we must push forward with continued plastics education. Just like physicians who must remain in front of medical breakthroughs, we must do the same with our engineers and program managers in this new industrial revolution.” Technical Training Enter Beaumont Technologies, a company originally founded in 1998 to commercialize a new plastic melt conditioning technology called MeltFlipper® that was invented and developed by John Beaumont. The company is also committed to educating the plastics industry, and has since added more products and services—including consulting services and plastics training (see MoldMaking Technology December 2012, page 26). David Hoffman, Beaumont’s Senior Instructor & Training Development Manager, points out that “Mold Design for Project Engineers” was designed as a direct result of industry feedback. “A molder near Pittsburgh, PA, called and asked if we had a course that taught the basics of mold design,” Hoffman recalls. “He saw a need within his company, stating that ‘I have several project engineers going out to review and approve molds, and
24 MoldMaking Technology May 2013
Photos courtesy of Beaumont Technologies, Inc.
Training Initiative’s “Mold Vs. Machine” Approach Boosts Moldmaker/Molder Relationship Beaumont’s Senior Instructor & Training Development Manager David Hoffman teaches his Mold Design for Project Engineers Course at Beaumont headquarters.
often they are not sure what they are looking at on mold prints nor do they know the right questions to ask to ensure the mold design meets basic requirements.’” Hoffman and his colleagues used these comments as the building blocks for the course, starting with a basic understanding of what plastics are and how they flow inside of a mold. “This is important for mold designers to understand so they can improve weld-line strength, minimize flow hesitation effects, and reduce part warp by properly selecting a gate location(s), for example,” he states. “The course then progresses into injection molding fundamentals—all with the purpose of building toward an understanding of the mold and its role in part quality. We talk about numerous aspects of the mold but spend a bit more time on a few key systems, such as the ejection system, cooling system, and melt delivery system.” Hoffman then takes the “mold versus machine” approach and discusses the many variables to evaluate to ensure the mold is capable of running in a given molding machine. “One particular topic that gets people thinking is clamp tonnage,” Hoffman comments. “There are many rules of thumb for estimating clamp tonnage in our industry. In this class, we evaluate four different methods for estimating the required clamp tonnage for a given part—while evaluating two different grades of a material—and come up with six different answers.” The course concludes with a section discussing common mold design details that are easily overlooked or misunderstood, but can create a world of headaches from the processing, part quality, and troubleshooting aspects, Hoffman adds. Initially, the course was developed with project engineers in mind, but Hoffman notes others are interested—including marketing personnel, sales people, purchasing managers, etc. “These people don’t necessarily need to know the intricacies of designing an unscrewing mold or stack mold, but they have a desire to
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Case Study / Training
Senior Instructor & Training Development Manager David Hoffman in the lab with Thogus employees during Beaumont’s Mold Design for Project Engineers Course.
do their jobs better and this includes a need to communicate more effectively with their peers and mold builders,” he states. “For example, a purchasing manager who is responsible for buying molds will be more knowledgeable about questions to ask a prospective mold designer/builder about their practices on cooling layouts, ejection and melt delivery systems to ensure the mold performs as needed in the cycle time quoted without excessive waste and without compromising the part quality and profitability of a project. As for the sales personnel, they will be able to better understand and communicate (and sell) what it is their company does when they are in front of prospective clients who may not be very familiar with the mold building or
injection molding processes. Having a sales person who is technically knowledgeable about the services they are selling earns trust (and business) from the client.” Thogus Engineering Manager James Michalenko is in complete agreement. “Knowledge is power,” he affirms. “Understanding mold design helps molders understand the limitations as well as the possibilities in mold design. Molders can ask constructive and critical questions with knowledge, and also conjure recommendations and make suggestions for improving designs. Another important aspect is that if molders are responsible for the customers’ tool design and approval, they should have knowledge to evaluate mold designs and approve them for the customer—which is the case for us most often than not.” Real Results Michalenko notes that Thogus considers training paramount to maintaining the highest molding quality. “Our employees seek training that expands their knowledge and that they believe will be able to be applied immediately, once they complete the training,” he states. “Their goal is to strengthen their expertise, raise their level of impact within the company, and bring value to themselves and what they can offer the company as a critical tool.”
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Thogus Business Development Manager Russ Wolff found that what he learned from the training can be applied both internally at Thogus and externally with the company’s customer base. “It has helped me communicate better with our program managers and engineers with respect to part requirements,” Wolff says. “I found the section on molds—specifically Mold Component Terminology, SPI Mold Classifications, Mold Material Classifications, Draft and Parting Line Considerations and Ejection Systems—to be very interesting. The Mold versus Machine section was also very useful, especially with the discussions surrounding clamp tonnage requirement; mold dimensions with respect to open and close heights; and injection rates and pressures.” Brad Krupa, Program Manager of Strategic Accounts at Thogus, notes that he is now able to contribute more advising tool drawing reviews based on what he learned at Beaumont’s training course. “Learning how plastic material moves and flows through a mold has changed the way I am going to approach plastic molding,” he comments. Beaumont’s Hoffman believes educating molders on the basics of mold design will ultimately improve the moldmaker/molder relationship. “Both have a common goal of providing a product that meets the needs of their respective clients,” he states. “If the molder is better able to specify what it is they need in terms of part requirements, understand why the designer did or did not do something in the design, and also offer ideas along the way—then this will only help both parties achieve that common goal.”
For more inFormation: Beaumont Technologies, Inc. (814) 899-6390
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Case Study / Software
Access video at end of article.
A Final Line Of Defense to Making A Quality Program And Product By Sherry L. Baranek M.C. Molds, Inc. (Williamstown, MI) is a blow mold manufacturer for the commercial bottle and medical industries while also specializing in the design and build of machine-specific trim tooling from concept through final product. The company has been using VERICUT CNC machining software from CGTech (Irvine, CA) for the past 18 years to ensure its customers receive the highest quality product. It was M.C. Molds President Bob Palazzolo who decided upon VERICUT after looking at several packages. According to CNC Programming Leader Bob Tuite, the department uses SURFCAM, Power Mill and WorkNC along with VERICUT to ensure quality of the machined product. “When I first started here, I could not understand the need for using VERICUT,” Tuite recalls. “I had been operating machines and programming for more than 35 years. I was used to sending single programs or looping, merging of multiple programs and tool pods to the operators. It took only a couple weeks for me to realize the importance of this VERICUT verification software.” According to CGTech Marketing Communications Manager Bryan Jacobs, “VERICUT interactively simulates the material removal process of an NC program. This information can then
M.C. Molds’ CNC Department uses VERICUT to process toolpaths. Pictured (left to right) is: Pete Pokryfki, Roy Holbrook, Seth Stover and Bob Tuite.
28 MoldMaking Technology May 2013
Photos courtesy of M.C. Molds, Inc.
Video
An inside look at the hand manipulation of the single programmed part to cut multiple cavities. VERICUT was used to verify the datum shifts and quality of the product before sending to the machines to run.
be used to correct inefficient motion or programming errors. VERICUT’s unique algorithm provides fast, accurate results and performance does not degrade with increased cuts, so it can process programs with millions of cuts and virtually any type of material removal technique. “The program supports G-codes and provides multi-axis support for milling, drilling, turning, grinding and EDM machines; simultaneous mill/turn on different spindles and workpieces; and automatic workpiece transfer to pick-off or sub-spindles,” he adds. The CNC department at M.C. Molds programs a single cavity at zero and then datum shift to make multiple cavity molds, Tuite states. “We not only program 2D and 3D, but also program 3+2 and full five-axis programs,” he elaborates. “For most of our jobs we do not run rough, semi and finish toolpaths; we only rough and finish. By doing so, we eliminate one more process—cutting our machining time down by at least 33 percent.” But skipping the semi-finishing pass means the programmers must be very aware of how much material they are leaving following the roughing process. “If, after running the program through VERICUT, there wasn’t any red appearing onscreen to show a problem, they believed it must be good to run. However, it didn’t mean it was programmed right.” Although VERICUT was simulating exactly what was programmed, Tuite believes that philosophy began to reflect negatively on VERICUT on the shop floor. “What looked good in VERICUT didn’t always mean what was happening in the shop—when it comes to things like cutter pull etc.—was right,” he says. “By not watching some of the toolpath in VERICUT, the programmer really doesn’t see if he has possibly left too much stock in the corners to finish. “We have so many jobs come through here, as well as many changes to existing jobs,” Tuite
Case Study / Software
adds. “We use it to verify that we are putting out to the floor exactly what is being called out on the prints, and work orders. For example, if a customer wants to increase the volume of parts the mold produces, we will pull up the original file and run the new changes over it to verify the programs are cutting when and where it was intended.” VERICUT is relatively easy to learn—and run, according to Tuite. He was able to train himself and employees in a few
weeks’ time. “It’s very hands-on,” he emphasizes. “Honestly, to be able to go home at night and not have to worry about the program failing or a major crash or any type of problem is a great relief to us all,” he emphasizes. Simulation advantages Tuite notes that although the initial programming time is about the same, the welding and scrap has decreased 75 percent—plus his operators have more confidence that what is coming to them is exactly what was intended. “We watch to see if we possibly need to optimize our roughing and re-roughing strategies, as well as tool and toolholder collision checking,” he explains. “Although most CAM software programs out there have cutter lengths holder checks, VERICUT also offers a real-time optimizing of tool and holder lengths,” he comments. “The software automatically adjusts tool lengths to holder to verify the proper tool length is sent to the operator. VERICUT is our final line of defense to making a quality program and product. It is icing on the cake as far as processing toolpaths for the build of molds.” “We use and rely on VERICUT to verify datum shifts, cutter path manipulation, and most of all quality,” adds Palazzolo. “I am happy to attest that VERICUT, the software and people have been very helpful with regards to our— and our customers’—success.”
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Successful, Profitable Mold Design Video
Access video at end of article.
What to consider when searching for an all-in-one mold design solution.
I
t is a common thread among today’s mold engineers that mold design software isn’t as user-friendly as it should be. There seems to be a wish list of ideal components that a “perfect” mold program should possess to help moldmakers face their mold design challenges head on. The largest problem mold shops are facing today is the confusing proliferation of CAD/CAM software types, all of which don’t function as a cohesive whole. There could be up to as many as 10 different types of software in one shop alone. With so many different software languages running at the same time, it is no wonder that shops must deal daily with increased production lag time along with troubleshooting and a flawed final product. If engineers could gather the basic tools needed to build a successful, profitable part in a fraction of the time,
34 MoldMaking Technology May 2013
Rendered image of a 2-cavity mold with hydraulic side action.
most—if not all—of the inherent software problems infiltrating today’s shop floor could be solved. Some basic tools needed for successful mold design are not without their flaws. A few of these shortcomings seem to be a recurring theme among frustrated designers. The struggle of dealing with a wide variety of file types while trying to maintain design accuracy is an everyday reality. While at the same time software that lacks a built-in plastic flow analysis option, which would provide basic fill and pack scenarios, would solve the issue of dealing with non-functional plastic parts. Completely customizable component libraries and mold design process builders are also tools that are missing in the design process.
These fundamental utilities would give the designer a huge
Images courtesy of TST Tooling Software Technology and VERO.
Rendered image of the fxed half of a complex mold tool showing multiple slides. Rendered image of the fxed half of a complex mold showing multiple slides.
competitive advantage while not succumbing to the typical CAD software. Having access to parametrics, when it makes sense as well as to a constantly updated library with the latest components and part numbers, would not only save time in the design process, but would also greatly improve product turnaround time. Another area that remains challenging to designers is Visit our CAD, CAM and Other Software Zone for more information on CAD, the organization of CAM, CAE, fow analysis and data mangeometry within agement software. the design system. Go to moldmakingtechnology.com/ The use of colors to zones for a complete list. separate and organize shut off areas, clearance areas, part shape and water lines enables shop personnel to easily identify what is critical and what is not. Mold software should not be limited to design only. It should easily flow through the various shop departments—meaning it should contain tip information, shrink values, electrode information, critical attributes, BOM and machining with the ability for 2D and 3D, and full 5-axis capabilities. A true software solution would also have the ability to easily analyze and modify supplied part data, modify part draft
Customizable component libraries provide the designer with a huge competitive advantage, greatly improving product turnaround time.
Learn More
Dynamic command selection and customizable map keys alleviate cumbersome icon command built into the interface.
moldmakingtechnology.com 35
Software
and add windage. Then be able to send part data back to the customer in their native format. The software should also have multiple viewers throughout the shop, which saves time, reduces distractions and costly prints—without any hang-ups along the way. This would prove to be advantageous not only to the designer and shop floor, but to the company as well. The improved production speed and part quality not only give a better finish on the product, but more accurate tooling
means that the manufacturer’s timescale is reduced, along with the number of set-ups producing cost-effective runs each and every time. Summary While researching specifics for a mold software solution for your shop make sure it is customizable to your design and manufacturing needs. Keep in mind universal file types, part changes, flow analysis, component libraries, quick and seamless translation to the shop floor and availability in one software package. The package should be both affordable and powerful enough to keep up with today’s manufacturing demand and increasing the shop’s bottom line, while keeping engineers productive and designs error-free. Remember too, that available first-class software support to answer questions or troubleshoot problems whenever they arise is critical to software success. With the right software you can be assured your shop can achieve its goals and increase its bottom line.
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Video: CAd/CAM: Core and Cavity Cutting http://short.mold makingtechnology. com/tstvisi
contributorS
Adam Rose is an Applications Engineer for TST Tooling Software Technology. His education includes Tooling and Die Design, and numerous other professional certifcations. Amanda Mielke has been working as a Marketing Administrator for TST Tooling Software Technology, LLC for three years.
Visit us at:
Eastec Booth 1052 amerimold Booth 132 ISO 9001:2008 & AS9100:2009 POCO® is a registered trademark of Poco Graphite, Inc.
36 MoldMaking Technology May 2013
For More inForMAtion: tSt tooling Software technology (248) 922-9293 tst-software.com
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Software
By Al Depoalo
Ramping Up to
Images courtesy of BobCAD-CAM.
Five-Axis Programming
Steps for making the transition from three- to five-axis machining.
I
s your shop ready to amp up your mold manufacturing capabilities by upgrading from 3-axis to 5-axis machining? With the trend of 5-axis becoming more prevalent, affordable and easier to use, machinists across the world are making the necessary adjustments to take their shops to the next level. Five-axis machining has some excellent benefits, including eliminating multiple setups, getting better tool performance, and obtaining better surface finishes; however, some shops are not sure where to start the transition. Where to Begin It all begins with design. Before a part can be programmed, the shop needs a CAD file from which to work. So if you want to ramp up to 5-axis faster, consider using an integrated CAM solution. This is an area of 5-axis programming that shop owners can take advantage of by working in their current primary design software. If your CAD vendor offers integrated CAM, you can short-cut the learning curve by working in your native CAD
38 MoldMaking Technology May 2013
environment. This is by far one of the larger hurdles a shop must overcome when transitioning to 5-axis. It is much easier, more cost-effective and less time-consuming to lay down some cutter path in the shop’s current design solution than it is for staff to learn the personality of an entirely new design package. Many CAD vendors recognize the need for CAM as an integrated solution, and professionals are predicting that it will become a standard in the next few years for CAD vendors to offer integrated CAM. Not only does it make program 2- to 5-axis more comfortable, but it also eliminates data translation errors; and for most, it offers a parametric environment that makes simpler work of late-stage design changes. Transition with Training Though using a CAM-integrated solution helps ease the transition from 3- to 5-axis, the true power and versatility of Photo: Multiaxis: 3 + 2 axis trimming.
Multiaxis advanced roughing toolpath for hand splint casting mold.
Machine simulation for hand splint mold.
Most machine tool vendors offer bolt-on 4-axis rotary tables. Starting with a 4th axis eliminates one axis that you have to consider while working. Not all mold machining is cavity work, and there is much supported machining that can be done on a 4th axis. Taking this step to enter the multiaxis world can ease the transition, and for some shops that may mean mastering 4-axis before moving on to 5 axis. If your CAM vendor subscribes to modular technology, it should be easy for you to add the 4-axis toolpath options and start cutting parts.
Multiaxis bottle mold simulation.
5-axis programming can only be found with software training. Throughout the years mold manufacturers have seen CAD/ CAM products promote mold-specific tools, which boast huge advancements in saving time and providing better designed and better machined parts; however, the reality is that no CAD/ CAM software can replace a good machinist. The gap between designing and programming parts correctly and actually machining the part correctly is filled by the honed skill set of a master moldmaker. This holds true with 5-axis programming. Because of the skill level needed, in order to truly ramp up from 3-axis programming to 5-axis programming, shop machinists will require training to be fully fluid in 5-axis machining. Transition with 4-Axis But don’t let the amount of training cause hesitation. Taking steps to utilize multiaxis doesn’t necessarily mean you need to start with 5-axis. If you can master the concepts of 4-axis, they will roll over to 5-axis, so for many shops this is a great stepping stone to becoming a 5-axis shop.
Transition with 3 + 2 Positioning A large portion of machine shops use 5-axis machines for 3 + 2 positioning, and for the mold manufacturer this may be a good start. Just like a 4th axis bolt-on, a trunnion table can be bolted to a VMC. This option gives you X Y Z B C program, 3 linear axis and 2 rotary—offering you the option for 3 + 2 or 5-axis simultaneous. This is just one of many machine configurations supported in 5-axis—known as a table-table setup. Being able to machine five sides of your part in a single setup can prove to be useful for electrode machining, and it will also allow you to start using the tilting strategies used with shorter tools. Working on smaller parts that are used in your mold design will allow you to master 5-axis techniques without the risk of crashing into a very expensive mold tools. Transition with Shorter Tools and Machine Simulation A key advantage to 5-axis programming is the ability to do more with shorter tools. The longer your tool hangs out, the more likely you are to experience chatter and poor surface finishing. By using shorter tools, shops achieve better finish quality; however, this also puts machinists in danger of collisions with the workpiece, toolholders, spindle and/or setup. This is the reason full machine simulation for 5-axis machining is so important. In a 3-axis environment, you may
moldmakingtechnology.com 39
Software
not have utilized full machine simulation, but when running full 5-axis, it’s the key to eliminating crashes. It also is used as a tool to help you design your setups and fixtures. Machine simulation is an absolute must in order to fully utilize a 5-axis machine.
LeArn more Visit our CAD/CAM and Other Software Zone for more information CAD, CAM, CAE and data management software. Go to moldmakingtechnology.com/zones for a complete list.
Using shorter tools, and having your machine rotate away from collisions to do so, may be part of your motivation to move to 5-axis. Another motivation for moving to 5-axis is simply to stay current with technology. Five-axis programming is becoming more and more common in the moldmaking marketplace, and available low-cost options make it affordable for shops to stay up-to-date and competitive. making the move There are clear benefits for moldmakers to migrate from 3-axis to 5-axis equipment and CAD/CAM software. What is unclear
40 MoldMaking Technology May 2013
for most users is the investment needed to take these concepts and make them a reality in their shops. This is where some low-cost solution providers shine because they ride technology trends and implement proven concepts for off line CAD/CAM programming. Through these efforts there are complete lines of CAD/CAM software for 2- to 5-axis programming available today for mold manufacturers of all sizes and levels, making it easier for them to invest in the necessary training to implement new toolpath options, which will reduce run times, improve surface finish and allow for better parts production. Implementing these new options will take time—time to learn the options in the software and knowing when to use them—but it is all part of the investment. The sooner you start, the sooner you’ll be taking advantage of them.
contributor
Al Depoalo is Partner Products Manager for BobCAD-CAM.
For more inFormation: bobcAD-cAM / (727) 442-3554 ext. 123
[email protected] / bobcad.com
Software
Video
By Andrea Giles
Access video at end of article.
Conquering the Quoting Challenge Adding the right multi-CAD viewer to your quoting process helps improve customer communication, secure new business, and save time and money.
Images courtesy of Kubotek.
Viewing and calculating tools like Draft Angle Analysis aid moldmakers in the quoting and manufacturing process.
The use of bounding boxes inside viewing tools allows moldmakers and non-CAD experts to more accurately quote raw material needs.
N
ame a problem that most mold manufacturers have in common. Many will answer that it is the timeintensive quoting process. A process often riddled with inaccuracies—from initial quote to quoting rework and design changes. Let’s not forget that many requests for quotes are submitted without perfect models, which further challenges profitability. In order to win more business, moldmakers need to better understand and communicate with their customers. No matter what CAD file formats you work with, adding the right multi-CAD viewer to your process can save you time and money. Following are common challenges the right CAD viewer can help you conquer head on: Poor RFQ Response Rates The right multi-CAD viewer can improve your response to the initial quote request. One reason is that you can actually quote the prospective customer. Many companies fail to respond to request for quotes (RFQs) in a timely manner—or maybe not even at all—because they cannot read the prospect’s CAD file format. A multi-CAD viewer will help you save time by not having to ask for a different file format than the one supplied in the initial RFQ. You’ll be prepared to receive almost any CAD file format, open it quickly to interrogate and inspect the design file. In addition, little or no CAD experience is necessary to use a multi-CAD viewer, which means you have options as to who can respond to RFQs. You will find that you do not have to waste time recreating drawings, which is a bonus if you are only an occasional CAD user. Your designated CAD resource is also freed up to work on actual production files instead of redrawing for RFQ purposes. Inaccurate Initial Quoting Initial quotes can be inaccurate simply because you are rushing to meet deadlines. In your haste, you might quote too high and lose the job to cheaper bids. Rush, and you might quote too low and end up eating the cost of your mistake. Your homegrown quoting method or system could be filled with too many assumptions that you have to hope you make correctly. Guess at the assumptions incorrectly and you hurt your profit margins. You might also fail to provide value-added suggestions to improve the customer’s design or manufacturability. A multi-CAD viewer will help stop the inaccurate guesswork and improve your quoting accuracy. Look for a multi-CAD
moldmakingtechnology.com 41
Software
also be able to submit a thorough job quote in a timely manner. Plus, a multi-CAD viewer with mark-up capabilities will give you time and a quick way to issue a quote that incorporates value-added suggestions.
A viewer makes tracking design changes easier. In this illustration, two parts can be viewed easily to show IS/WAS changes.
viewer that allows you to take detailed measurements or even gives you the option to section complex assemblies so that you can dig into hidden areas of the design. You will be able to improve the accuracy of your quote by zeroing in on cost-sensitive areas of a customer’s part. You will
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Requote Rework Headaches Requote rework and design changes after you’ve won a job can also be improved with the right multi-CAD viewer. Engineering change orders (ECOs) are almost always part of the moldmaking process. Responding to ECOs in a timely manner, comparing and verifying data changes and implementing them into the process faster will obviously improve product quality. Additionally, a customer-generated ECO might also result in a job requote. Using a multi-CAD viewer will ensure that you maintain, or even improve, your profitability for the work resulting from the design changes. A multi-CAD viewer will help you with the ECO process of any job by removing CAD data limitations, which means you are more agile to respond at any time during the moldmaking process. Experienced moldmakers often add value to the customer designs. Sometimes suggesting design changes to improve manufacturability will also save time and money for both you and your customers. The right multi-CAD viewer will let you mark-up customer-issued designs to highlight the specific areas in which your expertise will improve on the customer design—using the customer-issued CAD file or even exporting in various other formats to aid in your communication. The ease in communication will make you a mold manufacturer with whom it is easy to work. Your customer will have a clear understanding of your skills. Being able to work with customers, clearly stating and justifying value-added changes will likely improve your customer retention.
Learn MORe Visit our CAD/CAM and Other Software Zone for more information on CAD, CAM, data management software, mold fow analysis software and services. Go to moldmakingtechnology.com/zones for a complete list.
Limited New Business Opportunities Many moldmakers today are unfortunately at the mercy of several large customer accounts. If that customer goes away, the only way to stay in business is to expand your business base. Instead of limiting potential customers to only those who use compatible CAD software, a multi-CAD viewer will allow you to branch out to customers you may not have considered. Additionally, as a moldmaker, you put yourself in the driver’s seat of your business, responding to and working
with customers that you choose. Being able to work with any CAD data means you have more control over your business flow, and are not subject to the whims of your customers. excessive Training Costs With the right viewing tool, moldmakers will be able to diminish costs by reducing the need for multiple CAD packages—not to mention be able to keep costs under control for the related maintenance and training for each person using each separate CAD package.
Video: Benefts of a Multi-CAd Viewer http://short.moldmakingtechnology.com/ multicad
A multi-CAD viewer will help stop the inaccurate guesswork and improve your quoting accuracy. Multi-CAD viewers will also allow files to be viewed and worked on by a non-CAD user, which will save the cost of high-priced CAD experts. You will also be able to keep your company up-to-date with all of the latest versions of CAD files just as long as the multi-CAD viewer is maintained. Simply marking up files, printing out the mark-ups to share, saving them as a PDF for easy distribution or exporting to other CAD formats will make communication between you and your customer easier. And because multi-CAD viewers can be very low cost, just winning one more due to the use of the right viewing software will make for a quick return on your investment.
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Andrea Giles is Marketing Communications Manager for Kubotek USA.
For More inForMATion: Kubotek uSA / (508) 281-7057
[email protected] kubotekusa.com
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moldmakingtechnology.com 43
Machining
By Kyle Klaver
Enhance Mold Precision By Going Five-Axis Here’s how to manufacture large or high-precision, complex molds while maintaining efficiency.
E
fficient CNC machining capabilities are more important than ever for moldmakers seeking to maintain a competitive edge in today’s market. Oftentimes, large, heavy parts require intricacies that become increasingly difficult to maintain using a standard three-axis or four-axis horizontal machining center. Switching to a 5-axis CNC machine can provide users with the ability to manufacture large or highprecision, complex molds while still maintaining efficiency. There are many factors to be assessed when evaluating whether 5-axis machining is right for a particular application. The decision includes consideration of a combination of factors, including the particular machine, control, programming capabilities and process. It is very important to decide what goals will be accomplished by adding 5-axis machining to a mold shop. With goals clarified, the evaluation can proceed.
Make sure the machine tool and the control are able to handle the intricacies that are required for precise, accurate fnished molds.
Mold manufacturing demands high-performance machining. Period. Machine tools need to be highly engineered pieces of equipment designed with the capabilities to meet these performance standards.
Photos courtesy of Okuma America Corporation.
Look for High-Performance Design Mold manufacturing demands high-performance machining. Period. Machine tools need to be highly engineered pieces
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of equipment designed with the capabilities to meet these performance standards. A single-source provider having the ability to design a machine from the castings to the control is the best way to build a 5-axis that can truly deliver the required level of performance. A bridge-style design is a proven powerhouse for highperformance, 5-axis machining. When engineered with the right CNC control technology, it can allow for an insignificant amount of thermal growth. The thermal growth that is unavoidable can be controlled to a linear axis and can easily be compensated in real-time with control technology that manages spindle temperatures and machine thermal characteristics. Beyond the 5-axis layout of the machine, many companies are looking for turning tables included within the rotary table. This gives manufacturers the ability to turn cylindrical features instead of milling them, while retaining the accuracy derived from the turning process. Having the ability to turn cylindrical features provides a tremendous reduction in cycle time. The Control Factor Controls must be able to process as much information as possible in as short a time as microseconds. The ability to have
46 MoldMaking Technology May 2013
the control communicating precise data to the axis servos involves more than just the feedback of the encoder. While it’s true that accurate axis feedback is required, the control loop also needs to be able to read information from the thermal sensors, glass scale, control software, and rotary encoder to make decisions and respond quickly enough to compensate in real time. To do this, the control must have a processing loop in low single-digit microseconds.
Learn More Visit our Machining Zone for more information on milling, drilling, grinding, high-speed machining, fve-axis, hard milling, micro machining, large mold machining, multi-tasking, waterjet and laser. Go to moldmakingtechnology.com/zones for a complete list.
By accomplishing all of these things, the user never has the control chasing information. Without this feature, the machine falls out of real-time compensation and falls into post-time adjustments, leaving the user vulnerable to inaccuracies. In addition to high-performance controls, most moldmakers are looking for high-level programming functionality that allows
for easy, customizable adjustments. The tool center point control and the fixture offset function are two features that allow programmers to plan for part zero regardless of the setup on the machine. In the past, 5-axis controls did not have the ability to track the part zero and the tool tip location simultaneously without using the centerline rotation. It’s important to be aware of where the part existed on the machine in the z-axis. The XYAC would need to be dialed in to the true center of the two rotary axes. If for some reason there was an error in the fixture or part, this would render the part as scrap. Commonly, moldmakers batch parts based on errors, then run batch one, offset the machine and run batch two and repeat. This process is very time consuming and increases the risk of making scrap, delaying delivery and adding costs. Older and less advanced controls need to use inverse time to handle linear and rotary axis movement to achieve accurate results. Inverse time feed did not allow for feed changes at the control. Today, with Tool Center Point Control (TCPC), manufacturers can let the control handle all the feed command calculations, which will allow the programmer to program inches per minute (IPM) which is much easier for users. Fixture offset functions for 3+2 and simultaneous 5-axis with TCPC allows the programmer to more heavily rely on the control. This feature allows fixtures to be made and used without having to be perfect because the control Make sure the machine tool and will compensate for any errors that may occur. Many programs the control are able to handle the are now universal to machines intricacies required for precise, configured similarly. If a spindle probe is being used, it allows for accurate finished molds. further automation to occur, which in turn, lessens the chances for operator error. Other control features that can enhance processes are the tool tilt control or the posture control. This helps correct errors made by numerical control programs. In many cases, when toolpaths are driven by CAD, NC programs tend to have turnovers and fluctuations, causing the toolpath to produce erratic surface finishes and creating longer cycle times. The tool tilt control filters the NC program and corrects errors, thus improving finishes and reducing cycle times. Summary Making the switch to a 5-axis machine gives moldmakers the ability to manufacture larger, heavier molds without sacrificing precision or accuracy. Make sure the machine tool and the control are able to handle the intricacies required for precise, accurate finished molds. COntributOr
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Kyle Klaver is 5 Axis/AMPS Product Specialist at Okuma America Corporation. He has more than 27 years of experience in manufacturing engineering, including six years in a moldmaking environment.
For more inFormation: Okuma America Corporation / (704) 588-7000 /
[email protected] / okuma.com
moldmakingtechnology.com 47
Mold Maintenance/Repair
By James Bourne
In the Trenches Taking Mold Repair to the Next Level Improving mold repair efforts— whether you’re on the bench or managing—is not only a worthy goal, but also holds its own reward.
H
ow do you take mold repair to the next level? Is it better tracking mechanisms? Is it improved systems or processes? Is it improving the skills of the workforce? Is it being smarter or working harder? If I ask the right question, will it finally click? What is the right question? Does this require a paradigm shift? Why would I—should I want to— repair molds better (whatever that means) faster, more effectively, more efficiently? After almost a year, I found this list of questions that I had written down to stimulate my thinking about improving what I do on a daily basis. Several thoughts occurred to me almost immediately: hubris, cliché and group think, primarily. I’ll leave it up to you to imagine what part hubris played in my reaction—my personal demons won’t add anything helpful to the discussion. Thought is almost always the progenitor of change and improvement. Well, change may happen accidentally, but improvement is never an accident. Regardless, I know of no better stimulus to thought than to ask questions. Clichés and corporate catch-phrases aside, taking mold repair to the next level is a goal worth pursuing. Nobody sets a goal of being totally complacent, stagnant or unproductive. It’s in our nature to succeed and be productive, so improving mold repair efforts— whether you’re on the bench or managing—is not only a worthy goal, but also holds its own reward. Already I’ve expressed some thoughts generated by the last question. See? I was right, questions do spark ideas. Related to this methodology, I recently read a book that addresses the issue of asking the right questions. “Why? “Who?” and “When?” are rarely good questions because the answers are always the same: “It doesn’t matter.” “Me.” and “Now”. Better questions begin with “What?” and
48 MoldMaking Technology May 2013
“How?” as in “What can I do to improve the situation?” and “How can I help?” So, with a critical eye toward my own questions, here are a four more nuggets in no particular order. 1. It’s smarter and more diligently, but probably not harder. Whew, that was an easy one to answer. What does harder mean in reference to work? More physical and exhausting? Mold repair is not physically exhausting work. That’s not to say that at the end of the day you don’t go home spent. The exhaustion is mental. Your mind often has to be totally engaged in problem solving, decision making and painstaking execution. I know it’s trite, but the definition of insanity is doing the same thing over and over, and expecting different results. Working smarter means being cognizant of the instances in which you’re doing what you know will work in the short term, but ultimately will be ineffective in eliminating the problem. Taking a step back and saying, “I’ve done this before (numerous
times), so what can I do differently to correct this problem, so I don’t have to stand here tomorrow and do the same thing again? 2. Better tracking mechanisms? You bet. Steve Johnson has a slogan “Track the past, improve the future.” And it’s true. If you do repair work in a void or the often faulty theater of your memory, you may get lucky and hit a bulls-eye, but more likely you’ll just take another stab in the dark. Tracking data and analyzing it will help you make more informed (more intelligent) decisions. I shy away from making emphatic statements because on more than one occasion I’ve been wrong, but let me state this emphatically, “You will not improve the overall performance of your mold repair efforts without documenting issues, corrective actions and results, and analyzing the data.” 3. By improving the skills of the workforce? Do I even need to ask? Mold repair entails its own unique set of skills, how could improving those skills not help to reach the goal of taking mold repair to the next level? Identify the skills needed in your particular setting. Is it troubleshooting, machining, polishing, electrical knowledge, etc.? Hint, it’s probably not basic mechanical skills like righty tighty, lefty loosey. If it goes that deep, you may indeed need new people. 4. Paradigm shift? Yeah, probably, but more commonly it’s called changing the culture. Once you’ve taken a critical view of your operation and have come to the conclusion that
it’s not all that, the only alternative is to change—change something, anything. What you’ve done in the past is not achieving your goal, so change. Change is good. Anything you change, changes the culture because the culture is just the cumulative state of interpersonal dynamics and processes. Changing any part of either, changes the culture.
Learn MoRe Visit our Mold Maintenance and Repair Zone for more information on a mold tryout, welding, cleaning and retroftting. Go to moldmakingtechnology.com/zones for a complete list.
Be your own best friend—as opposed to being your own worst enemy—and initiate change. Don’t allow yourself to be pushed into it, and if you are pushed into change, don’t fight it. Go with it. Don’t let the unhappy experience of external pressure be the force that moves you into uncharted waters. Determine your own course of proactive improvements driven by an intentional plan. New and Improved is around the corner at Change and Status-quo. If you go straight through that intersection, the scenery will look much the same tomorrow as it did yesterday.
contributor
James Bourne is a tool repair supervisor and freelance writer.
FoR MoRe INFoRMaTIoN: James bourne (573) 701-9123 /
[email protected]
moldmakingtechnology.com 49
Product Focus / amerimold Exhibitor Product Showcase
June 12-13, 2013 Donald E. Stephens Convention Center, Rosemont, IL The Event for Mold Manufacturing amerimold is a trade show, technical conference and networking event that connects the mold buyer and mold builder. The trade show floor features exhibitors displaying products used for designing, building, repairing and processing molds. Products on display include: CAD/CAM software, 3D printers, machine tools (milling, drilling, grinding, EDM, etc.), cutting tools, mold components, mold materials, hot runners, surface treatment solutions, automation technologies, inspection/measurement tools, repair equipment, and mold manufacturing services. The amerimold technical conference delivers expert insights into the production and management challenges facing the mold manufacturer and molder through panel discussions organized into Engineer, Build and Maintain Blocks. Topics include: how to improve your design process, mold technology affecting your customer, successfully deploying technology, making real progess in workforce development, and mold maintenance and repair. The annual amerimold networking party, Leadtime Leader Awards presentation, and our new Knowledge Center show floor presentations will connect exhibitors and attendees for social and technical networking. The following pages will highlight some of the technology that will be on display. We will continue this amerimold technology coverage in next month’s issue. For details on the event, visit amerimoldexpo.com.
Parting Line Locks—SelfLube, Booth 225 SelfLube will display its array of parting line locks, which are made of shock-resistant S7 and rugged O1, SelfLube’s side, top and guide locks for molds and dies are also TiN-coated for hardness and durability, the company notes. For more information from Self Lube of Coopersville, MI, phone 616-837-9721 or visit selflube.com
Industrial Moldmaking Supplies—DME Company, Booth 305 DME Company, a manufacturer of mold technologies, will display its industrial supply offerings for precision and efficiency, including products such as the digital scale control system and dual flow product. DME’s digital control scale system helps remove and prevent scale-forming precipitate in cooling water— greatly reducing the associated maintenance and operation costs. Available in seven sizes for pipe diameters ranging from 1 to 12 inches, DME says the system delivers benefits that improve thermal transfer while also reducing fuel consumption and extend the life of components. Also being showcased, Smartflow Duoflow manifolds are robust extruded aluminum manifolds similar to the original Smartflow one-piece design. Featuring versatile mounting due to smaller size, mold-mount to speed mold change times and economical design for reliability, theses manifolds improve overall production, the company says. For more information from DME Company of Madison Heights, MI, phone 248-398-6000 or visit dme.net
50 MoldMaking Technology May 2013
amerimoldexpo.com
June 12 – 13, 2013, Rosemont, IL
Feedrate Optimization Strategies—CGTech, Booth 326 CGTech, the developer of Vericut CNC simulation software, will be presenting feed rate optimization strategies. The presentation will demonstrate the difference between high-speed machining versus high-efficiency machining. Some think of high-speed machining as simply running a CNC machine at maximum feed rates and taking multiple shallow passes. However, this strategy is often less efficient than taking fewer passes at slightly greater depths. Achieving the shortest cutting time is related to feed rates, but that is only one of many factors. High-efficiency machining—cutting a part in the least amount of time—is the real goal. Cutting at a greater depth is often more efficient, but the cutter may encounter an overloaded condition causing breakage or exceeding the horsepower on the machine. The key to achieving high-efficiency machining is to vary the feed rates to achieve the desired result for each cutting condition encountered. The presentation will provide an overview of the steps required to achieve the benefits of high-efficiency machining by using software to automatically optimize NC program feed rates. For more information from CGTech of Irvine, CA, phone 949-753-1050 or visit cgtech.com
Graphite Grades, Diamond-Like Carbon Coatings—Poco Graphite, Booth 132 Poco Graphite will highlight its graphite product line, which consists of more than 100 material grades for use in the EDM, glass handling, semiconductor and industrial market segments. In association with Entegris Specialty Coatings, the company also offers UltraC Diamond diamond-like carbon mold coatings formulated for improved wear resistance and increased lubricity to eliminate galling, and capable of running without grease or other lubricants. UltraC-HT is suited for tough applications and UltraC-L is formulated to improve release in the mold. Both coatings are only 1- to 2-microns thick and do not require a change in component dimensions. For more information from Poco Graphite, An Entegris Company of Decatur, TX, visit poco.com
Solid Carbide Ball-Nose End Mills—Data Flute, Booth 526 Data Flute will display its new Die Mold series of solid carbide ball-nose end mills for hard milling, mold applications. These material and applicationspecific tools permit machinists to use the newest, most productive, highspeed machining techniques to achieve superior finish, requiring little or no handwork, according to the company. For more information from Data Flute CNC of Pittsfield, MA, phone 413-499-3895 or visit dataflute.com
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Product Focus / amerimold Exhibitor Product Showcase
Mold Maintenance Training—ToolingDocs LLC, Booth 101 ToolingDocs performs multi-level maintenance certification training in both English and Spanish at its Mold Maintenance Training Center in north central Ohio and training capabilities in Canada and Mexico. Recently, ToolingDocs introduced its new “Hot Runner Maintenance and Repair Certification Course.” Other products include Maintenance Capability Assessments (MCA), On-Site Training (OST) and Total Systems Implementation (TSI). On Thurs., June 13, the company will host the Maintain block at the Amerimold Expo Conference, with Operations Manager Steve Johnson moderating a panel of industry leaders who will review some essential processes to mold maintenance/repair—e.g., cleaning, retrofitting and welding—but with an emphasis on the leadership and the resulting organized documentation, methodology, troubleshooting and training necessary for optimum performance of one’s fleet of tooling. For more information from ToolingDocs of Ashland, OH, phone 419-281-0790 or visit toolingdocs.com
Hybrid Tooling—JMMS, Booth 623 JMMS Inc. will showcase its hybrid tooling advances. According to the company, aluminum is becoming more popular for thermoplastic injection molds because it offers faster heat transfer and shorter cycle times than P20. It doesn’t match P20’s durability and maintenance specs, however, so JMMS engineers hybrid tooling with multiple alloys, including aluminum alloys like QC10. This hybrid tooling offers faster cycle times and lower development costs with the durability and reliability of P20 tooling, the company says. The hybrid molds combine materials for specific performance and production characteristics, including aluminum inserts for faster heat transfer and shorter cycle times, and shut-offs made from MoldMax, a copper beryllium alloy with higher density than traditional tool steels, for improved thermal conductivity.
Multi-Channel Optical Touch Probe System— Marposs, Booth 427 Marposs Corp. will present its Mida VOS optical touch probe system for use on large three- and five-axis machining centers. The multi-channel system consists of a receiver with integrated interface and a transmitter unit that is compatible with the full range of Mida touch-trigger probes. It is available in both a compact and modular version for application flexibility. As many as four transmitter/probe units can be used in an application with only one receiver, the company states. For machines with multiple spindles, two probes can be used simultaneously, making it is possible to implement two applications on the same machine. The Mida VOS is designed to reduce interference, and its modulated optical transmission system increases the operating range and transmission angle. Carbon extensions as long as 1 m can be used with the VOP60 modular transmitter/probe unit for reaching into deep bores. The robust system is controlled entirely by the machine tool via a simple PLC command, and the receiver can be easily programmed using a remotecontrol unit. For more information from Marposs Corporation of Auburn Hills, MI, phone 248-370-0404 or visit marposs.com
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For more information from JMMS, Inc of Easley, SC, phone 864-855-0450 or visit jmmsinc.com
amerimoldexpo.com
June 12 – 13, 2013, Rosemont, IL
Aluminum Mold Plate Alloys—Clinton Aluminum, Booth 425 Clinton Aluminum will show its line of aluminum mold plate alloys. Booth personnel will work with customers to provide them with the right alloys for their applications. The company says it has also been improving welding and texturing techniques for aluminum production tooling. Clinton Aluminum says it doesn’t just want to sell the material; it wants to be an active partner in helping its customers continue to improve their knowledge base and techniques. For more information from Clinton Aluminum and Stainless Steel of Clinton, OH, phone 330-882-6743 or visit clintonaluminum.com
Die Sinker EDM— Absolute Machine Tools, Booth 507 Absolute Machine Tools Inc. will be exhibiting its rigid AccuteX EDM “DS-550CM” Die Sinker EDM with an X,Y,Z working capacity of 20” x 16” x 14”. The work table size is 32” x 18”; and can accommodate workpieces as heavy as 2,970 lbs. Accutex designed the EDM using Finite Element Analysis to ensure high accuracy machining. Also on display from Absolute is the company’s AccuteX EDM “SP-500i” 5-Axis CNC Wire EDM, featuring the latest Microsparking Technology (MST-II) function for exceptional part finish. The company says this makes the machine suitable for aerospace and medical industries, which have demands for low recast and fine finishes. Absolute will also display its TMV-510G machining center from Tongtai Machine & Tool Co., Ltd. The TMV-510G is engineered for high-speed, efficient production of precision graphite electrodes and similar items. A fixed column/ moving table type machine, it features a high performance 20,000 RPM direct drive spindle that is oil cooled for thermal stability, and a 20 station highspeed arm-type automatic tool changer. The company’s TMV-1050Q-II ultra-high performance, heavy duty vertical machining center, also from Tongtai Machine & Tool Co., is said to be wellsuited for both high-volume machining applications as well as mold/die work. The machine combines speed, rigidity and precision as it features a 15,000 RPM direct-drive spindle, 1,890 ipm (47,250 mm/min) rapids on all 3 axes, as well as oversized servo motors and ballscrews.
Integrated Electrode Solution for EDM— Delcam, Booth 330 Delcam has extended its range of EDM equipment supported by its integrated solution for the design, machining and inspection of electrodes. Leading manufacturers include AgieCharmilles (Agievision and CT Millennium controls), Makino EDM, Mitsubishi Electric, ONA EDM, OPS-Ingersoll, Sodick and Zimmer & Kreim. The company says its scripts are the EDM equivalent of CAM programs for machine tools. They provide an automated process for the programming of the machine, instead of users having to program manually from a set-up sheet. The automated process is designed to be much easier and quicker, especially when a number of electrodes are being used on the same component. The company will also showcase the Delcam Electrode, a complete solution for design, machining and inspection. It combines Delcam’s PowerSHAPE CAD software, PowerMILL CAM system and PowerINSPECT inspection software. At the heart of the solution is a new file format— the .Trode file. This contains all the information for each electrode project, including not only the electrode design but also the machining and inspection information, plus the set-up sheets for its manufacture and use. Having all the required information in a single file is designed to simplify data management and increase overall efficiency. For more information from Delcam of Salt Lake City, UT, phone 877-335-2261 or visit delcam.com
For more information from Absolute Machine Tools Inc. of Lorain, OH, phone 440-960-6911 or visit absolutemachine.com
Modular Water Manifold—PCS Company, Booth 407 PCS Company will showcase its Kool Flow manifold, an anodized aluminum water manifold designed using six modular block assemblies. The flexible design is said to reduce assembly times and enables modifications “on the fly.” Each Kool Flow system can be easily modified to add or subtract ports as needed, and o-ring seals are installed to protect against leaks between modular block assemblies. For more information from PCS Company of Fraser, MI, phone 800-521-0546 or visit pcs-company.com
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Product Focus / amerimold Exhibitor Product Showcase
High-Feed Quad Cutters—Ingersoll, Booth 429 Ingersoll Cutting Tools will show its Hi-QuadF™ line of high-feed cutters— offered with a 13-mm and a 19-mm IC quad-style insert, which provides four cutting edges with a choice of eight different cutting edge geometries. The maximum depth of cut ranges from 0.088” for the 13-mm IC insert to 0.145” for the 19-mm IC insert. According to the company, premium insert grades coupled with optimal edge preparations ensure long tool life, even under the most demanding applications across the widest range of materials. A positive axial insert orientation creates a high-shear, free-cutting nature for the Hi-QuadF cutters. Chip thinning is leveraged to a factor of 5× when calculating feedrates. A new, robust insert screw design secures the insert in the pocket, ensuring cutter performance and insert seating stability. For more information from Ingersoll Cutting Tools of Rockford, IL, phone 815-387-6600 or visit ingersoll-imc.com
Mobile Laser Welding System—O.R. Laser, Booth 532 O.R. Laser will showcase its HTS EVO mobile laser welding system developed specifically for mold, tool and die makers as well as mobile service providers. The system is equipped with Lilly software to enhance its automation capabilities for use in aerospace, medical and production applications where rotation axis and wire feeder accessories are used. For more information from O.R. Laser of Elk Grove Village, IL, phone 847-593-5711 or visit or-laser.com
Alignment Locks and Other Devices— Progressive Components, Booth 105 Progressive Components will feature its Z-Series alignment locks, lifters, CamActions and parting line sequence control devices. In addition, company President Glenn Starkey will moderate the Engineer block of the conference on Wednesday, June 12. As a technical program chair for ANTEC, Starkey is representing the Society of Plastics Engineers’ Mold Making and Mold Design Division, which is sponsoring this conference block. He will lead panel discussions on technologies and best practices for critical decision-making on such topics as part/mold design, simulation and putting intelligence in the mold, and innovative ways OEMs, molders and moldmakers are working together. For more information from Progressive Components of Wauconda, IL, phone 847-487-1000 or visit procomps.com
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amerimoldexpo.com
June 12 – 13, 2013, Rosemont, IL
High-Speed Milling and Cost-Effective EDM— GF AgieCharmilles, Booth 205 GF AgieCharmilles will spotlight its Mikron HSM 200U LP (linear performance) milling machine and its Form 20 sinker EDM. The Mikron HSM 200U LP brings speed, efficiency, precision and true 5-axis simultaneous milling to the machining of small, highly complex components, according to the company. Linear motor technology in the main machine axes and optimized direct-drive motors for the B and C axes result in high precision and part surface finishes as fine as Ra 0.05 µm. Furthermore, the machine’s 50,000-rpm, 11.4-hp Step-Tec spindle also assists in providing surface finish and part detail. The Form 20 is designed for optimum connectivity capability, overall enhanced performance and a modern, compact design. The machine meets the cost-effective partproduction needs of today’s manufacturing industries, including general mold and die. It is also one of the first machines available with the new, recently developed AC Form HMI (human machine interface) CNC that centers on user friendliness and intuitiveness to significantly shorten the learning curve for beginner EDM operators. The company says the machine excels in burning deep ribs in such parts as mold cores. For more information from GF AgieCharmilles of Lincolnshire, IL, phone 847-913-5300 or visit us.gfac.com
Automated Sharpening—Darex LLC, Booth 139 Darex, LLC will introduce its XT-3000 Auto Sharpener. This new sharpener automates the drill sharpening function of the already versatile XT-3000 sharpener, the company says. This will enable faster and more consistent sharpening of many types of drills. Darex says the XT is already a workhorse sharpener with capability to not only sharpen drills but also countersinks, brad points, left hand drills, and more. The new feature will allow the user to simply align the drill, push the start button, and allow the auto sharpening feature to regrind the bit to specs within ANSI standards. It has the capability to sharpen drills sized 3 to 21mm simply easily and quickly. For more information from Darex of Ashland, OR, phone 541-488-2224 or visit darex.com
Hydraulic Locking Cylinder—DMS, Booth 517 DMS will display the BZ Hydraulic Locking Cylinder from HMM Solutions Inc. The company says the BZ Hydraulic Locking Cylinder offers a number of benefits over conventional methods of actuating slides including simplified design, machining, assembly and maintenance, as well as saving space in the mold. For more information from DMS of Oldcastle, ON, phone 519-737-6743 or visit dmscomponents.com
Mold Polishing and Coatings—Bales Mold Service, Booth 210 Bales Mold Service, a provider of mold polishing services and engineered coatings, will display Nicklon, a co-deposit of electroless nickel and PTFE for corrosion resistance and excellent part release; Nibore, which is engineered for superior lubricity plus abrasion and corrosion protection; and Diamond Chrome, the company’s hardest mold coating, with a tough 85 Rockwell rating. Bales will also show electroless nickel, hard chrome, welding and more. For more information from Bales Mold Service of Downers Grove, IL, phone 630-852-4665 or visit balesmold.com
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Product Focus / amerimold Exhibitor Product Showcase
High-Speed Machining Center—Hurco, Booth 247 Hurco will show its high-speed VMX42HSi mill, that is equipped with directdrive servos, an 18-k integral spindle and X/Y/Z travels of 42” x 24” x 24” to handle the rigors of high-speed machining. The automatic toolchanger supports HSK tooling and has a chip-to-chip time of 4.5 sec. The air-over-oil spindle lubrication is designed to distribute oil evenly and prevent bearings from grease starvation. The mill also is equipped with Hurco’s patented UltiMotion™ motion control system, which is said to reduce cycle time as much as 30 percent while simultaneously improving surface finish quality. This system uses complex software algorithms for motion planning instead of conventional hardware, optimizing look-ahead to as many as 10,000 blocks, the company says. The VMX42HSi is built to last and to retain accuracy, with larger linear rails that are mounted to a machined shoulder for increased rigidity. In addition, the rails are wedge-locked to the frame to reduce vibration instead of face-milled. Optimized for the advanced tool paths generated by CAM systems, the Hurco integrated control features a 64-GB solid-state drive, 2 GB of memory, a 2-GHz dual-core Intel processor and processing speed as fast as 2,277 bps. For more information from Hurco Companies Inc. of Indianapolis, IN, phone 317-293-5309 or visit hurco.com
Optimized Coolant System—Haimer, Booth 129 Haimer will display its new Cool Flash system, developed out of its existing Cool Jet system. The coolant is pressed out by several slots, floats around the cutting tool and cools up to the cutting edge. Haimer says the system can extend tool life up to 100 percent, eliminates balls of chips on the cutting tool, can be used for high RPM, and has optimized runout accuracy. In addition, the design enables no additional unbalance and no disturbing clearance. For more information from Haimer USA of Villa Park, IL, phone 630-833-1500 or visit haimer-usa.com
Flow Analysis Services—EPS FloTek, Booth 538 EPS FloTek will display a full line of flow analysis services performed specifically to minimize or eliminate "cut-and-try" start-up costs, produce better quality parts, reduce cycle time and reduce scrap rate. The company’s Moldex3D software offers a suite of products that accurately predict the conditions of plastic parts during the molding and curing process. Moldex3D offers many different modules and levels of software products, including eDesign, which can create a highly accurate analysis model using optimizing automesh with complete runner, mold and cooling system with just a few clicks.
56 MoldMaking Technology May 2013
According to the company, its professional advanced software level performs both 2.5D and 3D numerical analyses with accuracy. It allows the user to have full detailed control over each element of the surface and solid mesh of the model from the type of mesh to the shape and size. Add-ons allow users to move beyond standard injection molding, like compression injection, gas and water assist, co-injection, MuCell®, IC Encapsulation, and advanced hot runner. For More Information from EPS FloTek of Naperville, IL, phone 630-778-7773 or visit epsflotek.com
amerimoldexpo.com
June 12 – 13, 2013, Rosemont, IL
Vacuum System—CUMSA, Booth 328 CUMSA will present its vacuum system, which solves common problems such as trapped air in the cavity, long cycles, and sink marks on the plastic part. It works by removing the air from the cavity and leaving the space completely empty, allowing for perfect plastic fluidity and filling. Benefits of the system include lower injection pressure, energy and time savings, faster and shorter cycles, constant color and no marks. For more information from CUMSA (Comercial de Utiles y Moldes, S.A.) of Troy, MI, phone 248-850-8385 or visit cumsa.com
Nozzles for Side Gating—Ewikon, Booth 110 The Ewikon HPS III-MH nozzle product line offers a wide range of innovative solutions for the side gating of parts as well as for gating in confined spaces close to inner cores. All nozzle versions enable a cost-effective mold design with standard mold inserts and an ease of maintenance with parting line service ability, the company says. A thermally conductive tip design allows for parting line installation and tip cleaning with minimal downtime and without having to remove the mold from the machine. Ewikon says these advantages make the HPS III-MH nozzle suitable for demanding applications in the medical and packaging industries. The product line also offers linear block and radial block nozzles with up to 8 tips that are naturally balanced. Several gating angles are available including 90-, 60- and 0-degree hot tips. Also, a vertical valve gate facilitates direct valve gating onto the flange of a syringe body. Additionally, a special version of the product has been developed to handle long tubular parts such as syringe barrels and pipettes. For more information from Ewikon Molding Technologies, Inc. of Rockford, IL, phone 815-874-7270 or visit ewikonusa.com
Updated CAD/CAM Software—CGS North America Inc., Booth 119 CGS North America will demonstrate the latest version of its Elite CAD/CAM Software CAM-TOOL Version 9.1, highlighting its ability to machine a mold or die with minimal to no polishing. In response to user requests for the ability to separate roughing and finishing programs based on the length of the tool protruding from the holder, “Protruding Divide” was added in V8. In V9, that capability has been enhanced to make it more automated and simpler to implement. The company says a number of customers have always wanted to be able to use their Space Ball within CAM-TOOL, and that capability will now be available. In Z-Level multi-tool roughing, an option to minimize retracts has allowed the roughing time to be improved greatly, and five-axis drilling has been added to simplify drilling in multiple work planes on the same part. Version 9.1 also includes other improvements. For SolidWorks users, CG CAM-TOOL, an add-in to SolidWorks, has released Version 3.1 and will also be available for demonstration. The ability to apply 3D and 2D toolpaths directly to the SolidWorks model, getting the same high quality results as CAM-TOOL, is designed to minimize handwork and polishing on electrodes, inserts, slides, lifters and core and cavity components. For more information from CGS North America, Inc. of Oldcastle, ON, phone 519-737-6009 or visit camtool.com
Software Extension for Designing Core Cavity Blocks—Top Solid/Missler Software, Booth 236 Missler Software will demonstrate TopSolid’Split 7.7, an extension of TopSolid’Design that enables toolmakers to define and design core cavity blocks from an imported 3D plastic part or a design from the software. Once the model has been imported into TopSolid’Design, the user can prepare the part for injection by analyzing the draft angles of the model and globally or differentially controlling the shrinkage factor related to the material uses. TopSolid’Split automatically determines the best parting lines, which the user can redefine locally. The software extension also features intelligent wizards to automatically generate shut-off and external parting surfaces. It also can define all the inserts needed to account for production constraints at the core and cavity block split stage. For more information from TopSolid / Missler Software, Inc. of Addison, IL, phone 630-889-8055 or visit topsolid.com
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Product Focus / amerimold Exhibitor Product Showcase
Injection Tools and Services—Ahead Mold, Booth 463 Ahead Mold, a Shenzen-China-based ISO 9001:2008 certified injection moldmaker and molder will display its array of high-quality injection tools, plastic products and services. The company services a wide range of customers in a variety of industries including automotive, medical, electronic, communication and packaging. Countries Ahead Mold serves include Europe, North America, Australia, Asia and the Middle East. Company representatives will be at the booth to discuss attendees’ specific projects. For more information from Ahead Mold of Shenzen, China, phone 86-755-23222073 or visit aheadmold.com
CAD/CAM /CAE Software—TST Tooling Software Technology, LLC, Booth 113 TST Tooling Software Technology, LLC is the North American distributor of VISI CAD/CAM/CAE and VISI-PEPS Laser/Wire Software. VISI and VISI PEPS are world renown for the competitive advantage they provide to the tooling industry in the design and manufacture of plastic injection molds, 2D through five-axis milling, electrode production and others, according to the company. TST Tooling Software services a multitude of manufacturing industry sectors such as automotive, electronic, medical and aerospace. With locations in Michigan, Illinois, Ohio, Arizona, Oklahoma and Ontario, TST Software is better able to serve its clients throughout the US and Canada. With 145 years of combined experience, the team at TST Tooling Software is dedicated to improving business productivity, quality, and performance for a better bottom line, the company adds.
Two-Speed Sequential Valve Gating Technology— Synventive Molding Solutions, Booth 529
For more information from TST Tooling Software Technology, LLC of Clarkston, MI, phone 248-922-9293 or visit tstsoftware.com
For more information from Synventive Molding Solutions of Peabody, MA, phone 978-750-8065 or visit synventive.com
Tight-Tolerance Injection Molds—Mold-Tech, Booth 114 Mold-Tech Inc. designs and builds complex, multi-cavity, tighttolerance injection molds for manufacturing precision plastic, metal and silicone components. Mold types include auto unscrewing, hot runner, in-mold decorating, insert, MIM, micro, multi-shot, silicone and shuttle. Industries served include the medical, surgical device, automotive, electronics and consumer markets. Mold-Tech offers a range of services that include design for manufacturing, tool concepts for quoting, dedicated project management, in-house design, full in-house tool manufacturing, RJG-capable mold sampling and tool repair. To improve its wire and electrode capabilities, the company also has added a Makino DUO43 wire EDM and Makino V22 high-speed graphite machining center with 3R automation. For more information from Mold-Tech of Carol Stream, IL, phone 630-588-0400 or visit mold-tech.com
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Synventive Molding Solutions will feature its SynFlow® two-speed sequential valve gating hot runner technology, which provides molders with optimized plastic flow control, and solves common surface defect problems on large parts such as automotive bumpers and instrument panels. This unique, twospeed technology is an industry first and can be used to eliminate surface defects on large molded parts, the company reports. Common defects that SynFlow can solve include: pressure alteration marks, opposite direct gating marks, sink marks after coating and reduced adhesion of finishes. The results for molders are clean parts, reduced rejects, and better overall processing, the company adds.
amerimoldexpo.com
June 12 – 13, 2013, Rosemont, IL
Nozzles for Cold Sprue Applications—Incoe, Booth 536
Micro-Welding Laser System for Mold Repair— LaserStar Technologies, Booth 601 LaserStar Technologies will showcase its Universal Jig and 7700 series micro-welding laser system for plastic injection mold, tool and die maintenance and repair applications. The laser system can lay a bead as small as 0.0025” (0.05 mm); repair slots, pockets, radius contours and angles; repair polished, textured and engraved surfaces; repair thin walls with little or no warping; and repair parting line edges and heat-sensitive areas. Alloys include tool steel, aluminum, copper, titanium and powdered metals. According to LaserStar, the system produces a high-quality result, reduces the amount of handwork required before polishing and practically eliminates sink lines.
Incoe will highlight its new CSR series single nozzles specifically designed to replace worn or outdated cold sprue nozzles in existing injection molds with 1” maximum bores. Replaceable end caps are supplied with extra stock, providing the flexibility to machine to virtually any required dimension. An integrated heater design, used on the company’s DF Gold series of hot runner systems, incorporates two separate heating circuits, providing uninterrupted production and reliability. In the event of a single heater circuit failure, the second heater automatically provides continuous heating. For superior thermal performance, the heating element is profiled along the nozzle body to apply heat exactly where needed for optimal thermal control and repeatable material processing. The CSR nozzles are available in five standard lengths and are recommended for small to medium-sized molding applications of commodity-grade resin parts only. For more information from Incoe Corporation of Troy, MI, phone 248-616-0220 or visit incoe.com
For more information from LaserStar Technologies Corporation of Riverside, RI, phone 401-438-1500 or visit laserstar.net
Unscrewing Devices—Superior Die Set, Booth 223 Superior Die Set will showcase its Threadformer™ family of unscrewing devices. The Threadformer™ is a versatile yet simple core unscrewing system, which utilizes a powerful hydraulic motor and a fixed mechanical dead stop to achieve remarkable core positioning accuracy in a compact package, the company states. These made-in-the-USA machines are built to last with a rugged design that facilitates high production runs with minimal maintenance. Superior also supports its product with full technical support, providing 3D and 2D models as well as design assistance free of charge. The units are capable of unscrewing thread diameters ranging from 10-32 up to 80mm and thread lengths up to 70mm with the standard units. The flexible range of unscrewing units consists of three primary models all available in single or twin core variants, including a unique right angle unit capable of internal core cooling. The Threadformer™ can be adapted to the majority of lower cavitation requiring threaded core applications. Superior can also provide the threaded core along with the unit, taking yet another hassle out of unscrewing molds. For more information from Superior Die Set Corporation of Oak Creek, WI, phone 414-764-4900 or visit superiordieset.com
Polishing Media—Boride Engineered Abrasives, Booth 401 Boride Engineered Abrasives, a manufacturer of polishing stones, will display the latest addition in its mold stone lineup—the Golden Star. Made from select premium aluminum oxide grain and a proprietary treatment process, the Golden Star is of medium hardness with a fast breakdown offering quick material removal while contouring quickly and leaving a silky smooth finish, the company says. The Golden Star is designed to work on all tool steels and to perform exceptionally on EDM surfaces, milling and machining marks. The company also says this product does not require a lengthy pre-lubrication process and is terrific when used during hand stoning as well as with profilers. For more information from BORIDE Engineered Abrasives of Traverse City, MI, phone 231-929-2121 or visit borideabrasives.com
moldmakingtechnology.com 59
CUTthe CORD and connect live!
June 18–20, 2013 Pennsylvania Convention Center Philadelphia, PA
Industry Peers
New Technologies
Thought Leaders
Ideas and Inspiration
Connections like these cannot be made at your desk! Leave your office behind and expand your skill set at PLASTEC East this June. Increase your knowledge and your network by engaging with like-minded peers and industry thought leaders. Meet face-to-face with plastics professionals and find networking opportunities you won’t get in the office. Test drive the technologies of tomorrow. Interact with world-class suppliers to create custom solutions that are nowhere to be found online. Engineer fresh ideas from stimulating sources and face-to-face discussions.
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Product Focus / EASTEC
May 14-16, 2013, West Springfeld, MA
Workholding Products At Eastec in Booth 5453, Hardinge Inc. will be showcasing precision workholding products like spindle tooling for turning, milling, grinding, assembly, automation, inspection and process applications. Featured products include FlexC™ Vulcanized Collet Systems for CNC lathes. The flexible collet heads can be changed in less than 10 seconds using a manual compression wrench, the company notes. The Hardinge FlexC collet system is an ideal substitute for three-jaw chucks because it weighs less, has a lower profile and changes over much faster. The collet head has a gripping range of +/-.020” (.5mm) of its nominal size to allow for variation in bar stock without having to change the collet. Hardinge Sure-Grip® Expanding Collet Systems mount directly to the machine spindle or collet styles mount in the spindle of Hardinge colletready CNC lathes, collet blocks, indexers and rotary tables. There are no costly adapters to mount the arbor onto the spindle, the company states. One inexpensive self-contained unit provides the lowest-priced ID grip collet assembly in the industry. Standard products are in stock to grip inside diameters from 1/8” up to 4”, while custom manufacturing is available for non-round shapes, deep grips or with a recessed draw plug for gripping to the bottom of the bore.
Also on display are Hardinge Rotary Tables and Indexers for single and multi-part positioning. All Hardinge rotary products feature their exclusive collet-ready spindle that provides a wide variety of part gripping options to handle most part shapes and materials. For more information from Hardinge Inc. of Elmira, NY, phone 607-734-2281 or visit hardinge.com
Software/Parasolid Converter Software for CNC Mills/Lathes Southwestern Industries will introduce two advanced CNC software packages at Eastec in Booth 1706. Verify, available as part of the advanced feature option set for new TRAK lathes and TRAK mills with ProtoTRAK SLX and SMX controls respectively, allows machinists to quickly and easily proof ProtoTRAK programs prior to cutting chips. This valuable tool saves ProtoTRAK programming time, and reduces unnecessary scrap and rework. Parasolid Converter, available for bed mills, knee mills, and retrofits with ProtoTRAK SMX controls, makes it easy for machinists to generate ProtoTRAK programs from Parasolid 3D CAD files. It allows shops to meet the growing demand being placed on them by their customers to process 3D CAD files, and saves significant ProtoTRAK programming time. Both software packages will be exhibited with Southwestern Industries’ line of CNC bed mills, CNC lathes, and the award winning LPM machining center, designed for creativity in small lot machining. For more information from Southwestern Industries, Inc. of Rancho Dominguez, CA, phone 310-608-4422 or visit southwesternindustries.com
Workholding Devices Kurt will feature its expanded lineup of advanced workholding products for improved machining productivity at Eastec in Booth 5130. The SideWinderTM Vise provides vertical workholding for second operation machining in the same setup by easily mounting to the back of all Kurt industry standard six-inch vises. The SideWinder vise is ideal for all types of machining operations, including precision boring, tapping, drilling and finishing with accuracy on most part configurations. The SideWinder vise has a robust 80,000-PSI ductile iron body. Additional features include integral bracket with stabilization feature allowing mounting to the machine table on the movable end of the vise, and a workstop to allow vertical positioning of the part. The elevated position allows for longer reach machining that does not interfere with the operating envelope of the host vise. Featuring the original Kurt Anglock® design for decreasing jaw deflection, the new SideWinder vise distributes clamping force evenly and precisely across the full jaw surface. The Pull Type HD690vise line is available in standard and reverse jaw models and in manual and hydraulic versions. These vises feature a full 9-inch jaw opening, a wide stationary jaw, a taller body that produces less deflection, and a Quick Change movable jaw. The hydraulic model has a 1/4” stroke. All models feature the Kurt Anglock® design, which prevents parts from lifting upwards under heavy clamping loads. Now combined with the “pull-type” design that reduces stress under load, these models provide the ultimate in workholding rigidity and accuracy. For more information from Kurt Manufacturing Company of Minneapolis, MN, phone 763-574-8309 or visit kurtworkholding.com
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Product Focus / EASTEC
Machine Tool Technology Hurco machine tools will be exhibited at three EASTEC booths. Hurco distributor Brooks Associates will exhibit the five-axis VM10Ui mill and the mill turn TMM8i at Booth 1205; CCAT will exhibit the Hurco five-axis VMX30Ui at Booth 1354, and Greenleaf will showcase the 3-axis VM10i mill at Booth 5317. All of the machines feature the new design Hurco introduced at IMTS 2012. While the sleek exterior design of the Hurco machines with the new Hurco logo is the most noticeable difference from the classic Hurco machine tools, the inclusion of UltiMotionTM is the most significant technological difference. UltiMotionTM is only available on Hurco mills, both three-axis and five-axis. This patented feature reduces cycle time by up to 30 percent and significantly increases surface finish quality, the company reports. The five-axis VM10Ui has X/Y/Z travels of 21x16x19, X/Y/Z rapids of 945 inches per minute, a 20-station ATC, and the integrated Hurco control that supports both ISO/EIA NC programming and conversational programming. The TMM8i mill turn, slant-bed lathe with live tooling has X-axis travels of 7.8 inches and Z-axis travels of 20 inches, a maximum turning diameter of 10.1 inches, a maximum turning length of 17.9 inches, and a maximum bar capacity of 2 inches. For more information from Hurco Companies Inc. of Indianapolis, IN, phone 317-293-5309 or visit hurco.com
CNC Machine Simulation/ Optimization Software CGTech’s VERICUT 7.2 will be highlighted at Eastec in Booth 5344, that features many enhancements that reduce the time required for manufacturing engineers to develop, analyze, inspect and document the CNC programming and machining process. Along with proactively adding new features, CGTech developers and engineers have focused on implementing hundreds of customer-driven enhancements. The latest release also includes several new features that make commonly-performed tasks simpler and therefore significantly faster. Users will also take advantage of many new performance enhancements and code optimizations, ensuring it will likely run faster and better on their existing hardware. VERICUT is CNC machine simulation, verification and optimization software that enables users to eliminate the process of manually proving-out NC programs. It reduces scrap loss and rework. The program also optimizes NC programs in order to both save time and produce higher quality surface finish. VERICUT simulates all types of CNC machine tools, including those from leading manufacturers such as Mori Seiki, Mazak, Makino, Matsuura, Hermle, DMG, DIXI, and Chiron. VERICUT runs standalone, but can also be integrated with CAM systems such as Catia, NX, Creo Parametric (Pro/E), MasterCAM, EdgeCAM, hyperMILL, Esprit and GibbsCAM. For more information from CGTech of Irvine, CA, phone 949-753-1050 or visit cgtech.com
62 MoldMaking Technology May 2013
Solids-Based CNC Programming Solution At Eastec in Booth 5359, Access Manufacturing Systems will feature CAMWorks® 2013 the latest version of the solid-based CNC programming solution from Geometric. Ease-of-use is a critical factor in ensuring high productivity of the CNC programming team at any machine shop. The latest addition of the Synchronous Machining Module (SMM) in CAMWorks 2013 to handle multi-tasking machines with greater ease is one more step in that direction. Other new features include an optional upgrade to VoluMill™ V5.0 performance tool path to help reduce cycle times while maintaining tool life; enhanced set of APIs that simplify the ability to integrate and automate the design to manufacturing cycles; 3-axis machining from an STL file, saving time by creating multi-surface features; and auto correct of contour mill lead ins/lead outs. For more information from CAMWorks/Geometric Technologies of Scottsdale, AZ, phone 480-367-0132 or visit camworks.com
May 14-16, 2013, West Springfeld, MA
Five-Axis Machining Solutions Hermle Machine Company and its representative, INIRAM Precision will answer questions and discuss specific customer applications at Eastec in Booth 1034. The company will also show the C 400, a five-axis machining center incorporating Hermle’s popular patented gantry design, mineral cast base and rugged construction in a compact footprint and priced for entry-level shops and manufacturers seeking Hermle quality in a startup package, the company states. The machine features an X, Y, Z axis of 850-700-500 mm, respectively, a 15,000/18,000 rpm main spindle capability, and integrated 38-position tool changer. Additionally, the company will show the PW150 pallet change system with a C 22 machining center and the PW3000, which is capable of handling parts up to 2500 kg and has a five-axis capability. For more information from Hermle Machine Company of Franklin, WI, phone 414-421-9770 or visit hermlemachine.com
Five-Axis Milling Machine/EDM Technologies
High Performance NC Machine Simulation Software SPRING Technologies will demonstrate its recently launched NCSIMUL Machine 9 at Eastec in Booth 5517. With NCSIMUL Machine 9, SPRING customers are stepping into an NC simulation environment that is more realistic, intuitive, and integrated, with extended features dedicated to multi-axis and multitasking machining centers. Further, the software package has been developed to interconnect with other company-wide software systems, such as MRP, ERP, and MES, the company reports. This software offers users a unique experience where CNC realistic simulation, integrating all machine, tools, and material parameters, quickly becomes a day-to-day part of a manufacturer’s lifestyle, according to the company. It also features new ribbon technology navigation, enabling users to work more efficiently. Tasks are now accessed via tabs that break down into tasks and sub-tasks. The new interface has been specifically designed to work on touch screen devices to facilitate mobility. The intuitive and context-sensitive icons are presented as a rapid access bar, boosting programming productivity. The “NCSIMUL Machine hub” apps enable users to browse any shared jobs or replay NC simulations with one-click. Flexible project-based management, tree organization, project/article/sub-article, jobs copied between projects, simplified search mechanism, job templates are among the new features in NCSIMUL Machine 9. For more information from SPRING Technologies Inc. (NCSIMUL) of Cambridge, MA, phone 617-401-2197 or visit springplm.com
GF AgieCharmilles will demonstrate milling machines and wire and sinker EDMs in Booth 1236 at Eastec that provide high-performance, high-value machining capabilities—including the MIKRON HEM 500U milling machine, CUT 200 wire EDM, and FORM 20 sinker EDM. Ideal for machining aluminum, alloy and steel parts, the five-axis HEM 500U features a highly dynamic 12,000-rpm spindle and 30-tool magazine that provides a 2-second chip-to-chip time for high-speed continuous milling operations and increased spindle uptime. Additionally, a 20,000-rpm spindle and 60-tool changer are available. The machine’s trunnion table measures 19.7” (500 mm) in diameter and accommodates workpiece weights up to 440 lbs. (200 kg). It tilts +50 mm/-110 mm in the B-axis and rotates 360 degrees in C for 3 + 2 machining as well as 5-side positioning. Axis travels in X, Y and Z measure 19.7” (500 mm), 17.7” (450 mm) and 15.7” (400 mm), respectively, while a distance of 5.9” (150 mm) between the machine spindle nose and rotary table surface allows for ample maneuverability around workpieces. The versatile, workshop-oriented control for 5 (3+2) axis machining features an integrated digital drive control The CUT 200 wire EDM provides incredible speed and performance as well as high levels of quality and productivity, the company states—all of which gives manufacturers in industries such as aerospace, mold and die, medical and contract machining the ability to better control production costs. With a machine design that delivers versatility and high precision, the CUT 200 features extremely fast axis speeds and quick wire threading that reduces non-cut times. GF AgieCharmilles’ latest generation of spark generators allows the machine to cut up to speeds of 38”2/hour and up to 30-degree tapers in the Z-axis height, while also producing superior part surface finishes. Additionally, energy saving functionality and advanced software help further reduce operational costs and provide increased system connectivity. The FORM 20 provides the industry’s best price-to-performance ratio and also boasts outstanding connectivity capability, overall enhanced performance and a modern compact design, according to the company. The machine meets the cost-effective part production needs of manufacturing industries that include general mold and die, aerospace, automotive and communications technology. For more information from GF AgieCharmilles of Lincolnshire, IL, phone 847-913-5300 or visit us.gfac.com
moldmakingtechnology.com 63
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May 14-16, 2013, West Springfeld, MA
May 14-16, 2013, West Springfeld, MA
Linear Technology At Eastec in Booth 1206, Sodick will feature its linear technology in the Brooks Associates booth. The AG60L Sinker EDM features high speed and high acceleration linear motor drives, enabling an even and natural flushing condition that leads to perfect part accuracy, says the company. The menu-driven control automatically writes the NC code for the operator while inserting optimum cutting conditions. With its instantaneous responsive control and no flush technology, the AG60L makes what appears to be impossible, possible. The AG60L comes standard with Sodick’s 10-year positioning accuracy guarantee. The VZ300L Linear Motor Driven Wire EDM is Sodick’s cost-friendly model. This entry level machine maintains the quality you expect when owning a Sodick and achieves outstanding levels of accuracy and cutting speeds, comparable to that of high end Sodick EDM models. The VZ300L includes Sodick’s revolutionary 10-year positioning accuracy guarantee. The AG600LH Wire EDM is a high precision, high speed CNC machine with an additional Z height, giving it a unique height for its size. The AG Series Wire EDMs include direct drive linear motors with Heidenhain absolute glass scale
feedback, an energy saving circuit to save on power consumption, motion controller to provide simultaneous axis movement, on-board user-friendly Heart NC cam system, a rise fall worktank and a 10-year positioning accuracy guarantee. For more information from Sodick, Inc. of Schaumburg, IL, phone 847-310-9000 or visit sodick.com
Graphite Product Line Poco Graphite will show its premium graphite product line consisting of more than 100 material grades for use in the EDM, glass handling, semiconductor and industrial market segments at Eastec in Booth 1052. Highly recognized as the standard for EDM graphite electrodes, Poco produces materials with consistent properties and performance for maximum EDM efficiency and overall cost reduction, the company notes. Complementary EDM Technical Training and reference materials to optimize EDM applications is also availabe from POCO. In association with Entegris Specialty Coatings, POCO now offers UltraC
Diamond mold coatings, which is a DLC coating for improved wear resistance, increased lubricity to eliminate galling and provides the ability to run without grease or other lubricants, the company states. Variations of the UltraC Diamond include UltraC-HT for tough applications and UltraC-L to improve release in the mold. Only 1-2 microns thick, UltraC Diamond coatings do not require a change in component dimensions. For more information from Poco Graphite, An Entegris Company of Decatur, TX, visit poco.com
Five-Axis Developments Delcam will highlight its latest developments for the programming of five-axis machines in Booth 5326 at Eastec. While the company’s PowerMILL software remains its leading program for five-axis programming, FeatureCAM, Delcam’s automated feature-based CAM system for production machining, and the PartMaker software, for multi-axis machines and Swiss-type lathes, also offer extensive five-axis capabilities. It is no surprise that five-axis machining continues to become more popular as companies become more aware of its ability to boost productivity by increasing efficiency, improving quality and shortening delivery times, the company notes. Delcam systems have made programming for five-axis operations much easier over the years with more sophisticated simulation software to make it easier for the user to check toolpaths on the computer to minimize any possibility of collisions or gouges, the company notes. For the latest PowerMILL release, the main change in the five-axis capabilities has been to increase the number of options for tool-axis definition. For faster toolpaths, the lead and lean angles can now be defined relative to a contact normal. In addition, better control is now possible for the tool-axis definition when using the To or From a Point, Line or Curve strategies. These improvements will make it easier for users to control the contact angle
between the cutter and the part, and so set the optimum cutting conditions for efficient machining and high quality surface finish. The resulting NC programs can be made even more efficient by automatically reordering the toolpaths, using the tool number or tool diameter, to reduce the number of tool changes, or using a specific workplane, to minimize set-up changes. For more information from Delcam of Windsor, ON, phone 877-335-2261 or visit delcam.com
moldmakingtechnology.com 65
Product Focus / EASTEC
Cutting Tools Lineup BIG Kaiser Precision Tooling Inc. will showcase its full lineup at Eastec in Booth 5248, including the Speroni Futura presetter. The entire KAISER EWD Series of digital boring heads will be displayed— including the new 310 medium diameter and 318 large diameter programs, which complement the most popular 112 digital program. For the entire EWD program, the robust measurement system shows precise linear movement of the tool carrier in both directions on a built-in digital display offering adjustments of ø.00005” or ø.001mm. BIG Daishowa’s newest solution in extended reach arbor technology, the Smart Damper, features a unique dynamic damping system that eliminates vibration and instantaneously reduces chatter for higher productivity in deep hole finish boring and extended reach face milling. Also on display will be the new Hydraulic Chuck Super Slim line of tool holders—an expansion of the high performance Hydraulic Chuck line. The slender body eliminates interference in confined areas—ideal for five-axis precision machining. The Mega Synchro Tapping Holder for rigid tapping has also expanded to include solutions for micro taps and large taps. Also on display from BIG Daishowa are three high performance indexable cutters. The R-Cutter is an ultra high feed front and back radius chamfering mill which features high rake angles that reduce cutting resistance and minimize burr generation. The insert design allows for four indexes, and is available with radii of .02”-.16”. The BF-Cutter is a back spot facing tool for cap bolt holes M6-M16. It utilizes the world’s smallest indexable square insert, and is coolant through to securely cool down the backside cutting area. The Speed Finisher is a new high speed face mill for aluminum and cast iron which offers mirror-like surface finishes. Each insert cutting edge is height adjustable to within 1 micron of each other. For more information from BIG Kaiser Precision Tooling Inc. of Hoffman Estates, IL, phone 847-228-7660 or visit bigkaiser.com
High-Performance Roughing/Finishing End Mills At Eastec in Booth 5140, Emuge Corp. will feature High Performance TOP-Cut™ Roughing and Finishing end mills. With one Emuge-Franken TOP-Cut carbide end mill, both roughing and finishing operations can be performed, significantly reducing vibration, and reducing the number of tools and changes, the ccompany notes. The TOP-Cut end mills are optimized for maximum versatility in machining. Variable helix angles eliminate harmonic oscillation to greatly minimize vibrations and improve surface quality. Even in the most diverse materials, a tough carbide substrate, combined with optimized micro-geometry and a high-heat resistant TiALN coating, guarantees a great degree of process safety and long tool life. For maximum efficiency, the stable design features a recessed neck. TOP-Cut™ Roughing and Finishing End Mills join the High Performance TOPCut Carbide End Mill Line. Emuge TOP-Cut End Mills are available in a full range of inch and metric sizes, lengths, and in various types. For more information from Emuge Corp. of West Boylston, MA, phone 508-595-3600 or visit emuge.com
66 MoldMaking Technology May 2013
May 14-16, 2013, West Springfeld, MA
Advanced Tooling Systems
Machining Software At Eastec in Booth 5249, CNC Software will show Mastercam X7, which includes new capabilities like the new Mill-Turn product, Renishaw Probing and more. Mastercam’s Mill-Turn product makes machining on today’s high-powered turning centers and full-function machining centers simpler and easier than ever before. Mastercam Mill-Turn streamlines the programming process with intelligent job setups that are keyed to the exact machine in your shop. Intelligent work plane selection makes it easy to select the proper spindle and turret, and program your part with Mastercam’s proven milling and lathe toolpaths. Mastercam X7 integrates Renishaw’s Productivity+ for in-process gauging. This uses a measuring probe on a machine tool to determine fixture offsets, orientation, and critical dimensions. Probing eliminates the need for tool presetters, expensive fixtures, and manual settings with dial indicators. It allows for machine offsets to be automatically adjusted, even during the machining process, to further enhance the manufacturing process. The Lathe Dynamic Rough toolpath is designed for hard materials cut with button inserts. The dynamic motion allows the toolpath to cut gradually, remain engaged in the material more effectively, and use more of the surface on your insert, extending tool life and increasing the cutting speed. For more information from Mastercam / CNC Software of Tolland, CT, phone 860-875-5006 or visit mastercam.com
At Eastec in Booth 5558, REGO-FIX will demonstrate some of its most advanced tooling systems, like slim-nose powRgrip 6 (PG6), the innovative secuRgrip® and the new millTite milling chuck holder—all of which deliver the well-known REGO-FIX Swiss precision, strength, ease of use, and reliability necessary for tackling today’s demanding part machining operations, the company states. Unlike other clamping systems that use heat or hydraulics to expand the material, the REGO-FIX powRgrip (PG) safely uses the mechanical properties of the toolholder material to generate tremendous gripping force with runout below 0.0001”. As a result, manufacturers can expect long cutting tool life and superior surface finishes, according to the company. As part of its PG system, REGO-FIX offers multiple holder nose-profile options, including that of the recently developed slim-nose PG6 toolholder. It has a minimal outside diameter of 0.4” and a clamping diameter ranging from 0.008” to 0.125”. Because of its small, slim design, the PG6 provides less tool interference, easily machines tight pockets and delivers high levels of productivity. Furthermore, the PG6 has a run-out accuracy of 0.0001” and provides quick, simple and safe tool changes, as well as superior vibration dampening, easy tool presetting, longer tool life and unmatched clamping forces. Another recent addition to the PG family is the secuRgrip, an option for difficult machining applications that require advanced cutting tool security. secuRgrip utilizes PG’s tremendous gripping strength in combination with a patented locking key system and threaded cap. These two additional levels of cutting tool security bring enhanced confidence to specialized applications such as expensive castings or complex parts requiring long machining cycle times. For more information from REGOFIX Tool Corp. of Indianapolis, IN, phone 317-870-5959 or visit rego-fix.com
CNC Programming Software At Eastec in Booth 5426, Gibbs and Associates will show the new features and enhancements planned for GibbsCAM 2013. New options include two five-axis multiblade options that simplify programming and machining bladed turbo machinery components; and five axis porting that provides specialized functions to make programming faster and easier. Features and enhancements include improved support for Swiss-style machining, a mill feature, surface flow, profiler modes, drilling and thread milling patterns, lathe threading and thread whirling, and lathe plunge roughing. For more information from Gibbs and Associates of Moorpark, CA, phone 805-523-0004 or visit grdnr.GibbsCAM.com
moldmakingtechnology.com 67
Product Focus / EASTEC
Range of Machining Technologies At Eastec in Booth 1426, MC Machinery Systems will have a complement of metalcutting machines, like the MCV 1000 machining center that features an 8,000 RPM spindle and CAT 40 tooling. The MCV performs well in a wide variety of applications, including but not limited to fixtures, mold base and secondary operations. This line can also be equipped with a ZF Gearbox, giving it the ability to achieve four times the torque of a standard motor. The MV2400-S Advance wire EDM will also be demonstrated. This EDM features the M700 series control with 15” touch screen, providing easy user interface. It also showcases Mitsubishi’s continuous dedication to high precision through several new innovations, including a new non-contact Cylindrical Drive System. The MV Series features many new improvements in machine construction, auto-threading, internal machine communication, power supply technology and operating cost reduction. Also on hand will be the Mitsubishi EA8A Advance sinker EDM. This machine features the new M700 series control with 15” touch screen and FP80V energy saving power supply, reducing electrical consumption by 20 percent as compared to the previous FP model. The combination of the standard granite table and PS circuit provides fine satin surface finishing anywhere on the table surface. For more information from MC Machinery Systems, Inc. of Wood Dale, IL, phone 630-616-5920 or visit mitsubishiworld.com
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68 MoldMaking Technology May 2013
May 14-16, 2013, West Springfeld, MA
Laser Welding System Is Mobile
High-Feed Cutters
O.R. Laser will show an evolution of mobile laser welding systems at Eastec in Booth 2105. The company was motivated by its customers’ experiences and combined with years of development, a completely redeveloped “better way to work” is now available. The HTS EVO mobile laser welding system was developed and intended for mold, tool and die makers as well as mobile service providers; and comes with Lilly software to enhance all automation capabilities for use in aerospace, medical and production applications where rotation axis and wire feeder accessories are used.
Ingersoll Cutting Tools introduces the Hi-QuadF™ high-feed milling family at Eastec in Booth 5363. This innovative and highly versatile cutter line is offered with a 13mm and 19mm IC quad-style insert. The insert provides four cutting edges with a choice of eight different advanced technology cutting edge geometries, the company reports. Premium insert grades coupled with optimal edge preparations ensure long tool life even under the most demanding applications across the widest range of materials. The maximum depth of cut ranges from .088” for the 13mm IC insert to .145” for the 19mm IC insert.
For more information from O.R. Laser of Elk Grove Village, IL, phone 847-593-5711 or visit or-laser.com
For more information from Ingersoll Cutting Tools of Rockford, IL, phone 815-387-6600 or visit ingersoll-imc.com
MoldMaking Marketplace
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moldmakingtechnology.com 69
End Market
REPORT
By Bill Wood
Automotive and Consumer Solid Year Expected for automotive tion sector was a drag on overall economic activity. But this trend was clearly reversed in the second half of 2012, which means that a proper economic recovery can now finally start to unfold. Trends in the housing market are a primary factor in rising household wealth, and also in improving access to credit for most consumers and small businesses.
U.S. Motor Vehicle Monthly Assemblies Millions of Units, Annual Rate
Data source: Federal Reserve Board Forecast: Mountaintop Economics & Research, Inc.
Our latest forecast calls for total motor vehicle assemblies in the U.S. to reach 11.0 million units in 2013, which will represent a 7% annual. For the record, there were 10.3 million units assembled in 2012, and this was a jump of nearly 20% when compared with the total from 2011. As the chart illustrates, 2013 is expected to be the fourth consecutive year in which this sector has experienced solid growth. And if our forecast for 2013 is correct, total assemblies in the U.S. will still be one million units shy of their pre-recession level, which consistently hit about 12 million units per year. The average age of all of the motor vehicles in the U.S. is still quite high by historical standards. So there is pent-up demand from consumers and small businesses who are awaiting better economic conditions. We expect the overall economy to grow by 2.5% this year and 3.5% next year. This trend of gradual improvement will be sufficient to foster steady growth in motor vehicle demand for the foreseeable future. The U.S. market’s ever-rising awareness of the issues pertaining to energy independence and carbon emissions will continue to spur demand for lighter, more fuel-efficient vehicles and also vehicles that use non-traditional power sources such as natural gas, bio-diesel and electricity. There will be rising demand for small trucks and utility vehicles from contractors and other construction workers generated by the accelerating recovery in the residential construction sector. Until last year, the construc-
Output of Consumer Goods Still Underperforming for most middle-class households to adjust to the fact that their paychecks are now a couple of hundred bucks lighter each pay period. Some of this direct hit to consumer pocketbooks might eventually be mitigated by lower energy prices or rising home values, but for at least the first half of this year it will curtail their spending on consumer goods.
Consumer Products - U.S. Industrial Production 12-Month Growth Rate (percent)
FOR mORE inFORmaTiOn: Bill Wood, MoldMaking Technology’s Economics Editor / Mountaintop Economics & Research, Inc. (413) 772-6436 /
[email protected] / plasticseconomics.com
70 MoldMaking Technology May 2013
Data source: Federal Reserve Board Forecast: Mountaintop Economics & Research, Inc.
Total U.S. industrial production of household consumer goods (excluding high-tech, autos, and energy) is forecast to expand 1.7% in 2013. This follows an increase of 1.4% in 2012. These rates are lower than the overall rate of growth in the U.S. economy. Total GDP, after adjusting for inflation, grew by 2.2% in 2012, and we expect it to increase by 2.5% in 2013. Historical analysis indicates that growth in demand for consumer goods correlates closely with growth in the overall economy. The slower growth in U.S. consumer goods production in recent years is due to the fact that many types of these goods are still being imported. The problem with imports and our overall trade deficit in consumer products will take a long time to solve, but there are several near-term factors that will also affect U.S. manufacturers this year. The most obvious are the persistent trends of agonizingly slow growth in both new job creation and personal incomes. The lackluster labor market has resulted in a decline in overall labor force. It will take at least another year or two before we get more robust improvement in the employment data. Until then, gains in consumer spending for all types of goods will be constrained. Another short-term negative factor is the recent dip in consumer confidence that is due to the problems emanating from policymakers in Washington DC and the recent rise in payroll taxes. It will take a few months
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Editorial advisory Board (EaB) The EAB enhances the standing of the publication and strengthens its professional integrity through the active involvement of its members Tim Atwood, Technology Manager MSI Mold Builders
Tom Lynn, Tooling Engineer, Plastics General Electric, Appliances & Lighting
Vic Baez, Plastics Technology Manager Rockwell Automation
Dan Mishek, Managing Director and Co-Owner Vista Technologies LLC (VistaTek)
Andrew Baker, Project Manager Byrne Tool & Die, Inc
Ralph Neufarth, Senior Engineer Proctor & Gamble, Global Package Development
Tim Bartz, Vice President of Operations Mold Craft, Inc
Tim Peterson, Vice President Industrial Molds Group
John Berg, Group Marketing Director MGS Manufacturing Group
Steve Rotman, President Ameritech Die & Mold
Wayne M. Hertlein, Program Manager Wilbert Plastics Services
Michael Walter, President MET Plastics, Inc
David Hirt, Tooling Engineer Ventra Plastics
Mike Zacharias, President Extreme Tool & Engineering/Cosmos Tooling Solutions
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tip Software
By Dr. Marco Thornagel When it comes to injection molding, it is common for companies to rely on trial-and-error methods to solve production problems. Without process simulation, operators suggest a mold configuration, which “should work” for a specific part geometry, based on experience. Factors such as tempering or processing times are defined later during the first production trials. It is not uncommon to find molds that require several rework stages, as well as parts with quality issues where the causes for these issues are not well understood. Simulation technology can help avoid all these typical processing problems while saving significant time and effort during the development of a new mold. When utilizing the approach of process simulation all the elements of the mold can be included. This allows the molder to run a virtual production—including all the process stages (preheating of the mold, injection and curing) not only over one cycle, but over several production cycles. With this process, the performance of a mold design can be evaluated completely before the steel is even cut. Historically, conventional injection molding tools to predict the filling of the cavity have been relied upon. Many still think this is all simulation can do for them. However, simulation tools available nowadays are far more powerful. Besides filling, the curing reaction can be accurately predicted, and the thermal behavior can be exactly anticipated. Simulation can make a company achieve its production goals faster, being more profitable. It can analyze different variables of the design of a new mold. After determining the desired geometry, the process starts with the selection of the injection point or gate type. Understanding the flow behavior, as well as quality issues related to weld lines, air gaps or jetting, the runner geometry can be defined. In this stage, different aspects including cavity balance or the pressure requirement can be predicted. Once the part and runner are defined, the tempering of the
72 MoldMaking Technology May 2013
Image courtesy of SIGMA Plastic Services, Inc.
How to test Mold Design performance
Simulation can be used to support the complete mold design process. All elements in the mold are considered, so that an exact prediction of the processing conditions can save production time and troubleshooting effort.
mold can be designed. In the simulation, the tempering elements can be precisely included: it is possible to define their exact location in the mold, as well as the material and the electric power. Even the control system can be defined. Instead of assuming a mold temperature in the simulation, the exact thermal condition of the mold is predicted, including the way it fluctuates over time. After the effect of the desired tempering system is simulated, factors in the mold that can compromise part quality can be identified. Cold spots in the mold where the material cures too late or irregular temperature distributions, which can produce different curing degrees for parts produced in different cavities, are some examples of the virtual troubleshooting that can be achieved with process simulation. ConTrIBuTor
Dr. Marco Thornagel is executive director of SIGMA Engineering GmbH / Germany.
for More inforMation: Christof Heisser or Matt Proske / SIGMA Plastic Services, Inc. (847) 558-5600 /
[email protected] / 3dsigma.com
Versa-Slide® Te Choice of America’s Best Mold Makers
Te most versatile slide on the market Te Highest Quality • Slide Faces Available 68 Sizes • “All” Sizes In Stock
Standardizing the Industry
1-888-666-4755 www.omnimold.com
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Made in America
