5 Axis Machining Now Benefits Injection Mould Making

Copyright (c) 2010 Nadine DavisInjection mould making is taking a leap forward in

terms of productivity and accuracy through the acceptance of 5 axis machining technology which has been benefiting other sectors of the manufacturing industry for some time. Being able to machine all 5 sides of a component using the same set-up saves time and reduces the possibility of human error. To be able to transfer these benefits to injection mould making has been a boon for this section of the manufacturing industry. Finding the correct work piece holding system is crucial to the success of the process, with quality engineered solutions emerging to delivery productivity gains and vastly reduce waste.There is a steep learning curve with 5 axis machining for new operators, and one of the areas where a new player can have difficulty is in holding the work piece so that five sides of the piece can be machined effectively. The following information on the two most common methods may be of assistance to new operators:Mechanical Clamping Systems:These are the most common systems, and resemble a vice but with extra clamping force. This method allows minimal interference with the cutting area and enables the exposed surfaces to be machined with a high degree of accuracy.This clamping system can hold small to medium sized work pieces quite easily, but for larger pieces, a riser is recommended in order to reach the work piece. These are not common type clamps but highly engineered pieces of equipment which apply force were it is most needed. Additional security is provided by the use of pointed grippers in the vice jaws.Magnetic Systems:A common method is to fix the work piece to a magnetic pedestal. Because the work piece is then elevated, the 5 sides can be machined in one set-up, which also dramatically reduces the margin for error. The actual machining processes don't change the magnetic pull. This is because the 5 axis high speed methods require a much higher spindle speed, far lighter chip loads and faster feeds overall. These reduce torque and cutter pressure, so there is no danger of the work piece moving while being machined.Another method is the use of magnetic pallets which enable the movement of the work piece from one machine to another. This method requires careful planning and design at the outset, but pays dividends in the savings gained during the manufacturing process.Business owners who invest in high-end 5 axis machines and then skimp on the cost of work piece holding systems will not get the full benefit of the efficiency and productivity gains available with this machining technology. Operators at CNC Townsville workshops are already proving that these systems are worth the investment.

5 Axis Machining Now Benefits Injection Mould Making

By: Nadine Davis

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