subject: Micro-milling Micro-mold New Opportunities - Mold - Hardware Industry - Radio Controlled Digital [print this page] If there is any hint of the iPod, it is that the smaller the better. iPod has become a successful occupation of the market one of the most popular gadgets for Apple to bring a lot of profit while the stock prices to new highs. Not only in the original iPod had a small appearance, but it is to make it smaller. IPodmini model is now replaced by smaller iPodnano models; and then a very small iPod models.
Not only the iPod is becoming smaller. Computer and TV Machine has constantly become thinner. Advances of medical equipment, a growing number of micro-devices can be installed in our body; even a tiny camera can walk through the body.
Is not only what is becoming smaller, they are equipped with more components, can provide additional power and functionality. Micro-parts in the air, Car , Biomedical, electronics, information technology, optics and telecommunications industries with a wide variety of applications.
Product development are all these small parts and products are higher demands. In order to continuously reduce costs, most of these small parts used in Mold Production. These trends raise all kinds of mold makers with new challenges, ranging from the use of new space-age materials to special die coating, with a diameter of 0.1mm of Tools Milling parts and obtain sub-micron precision.
The same time, the inherent complexity of micro parts for mold manufacturers new opportunities. When simple and moderately complex mold was transferred to countries with low labor costs, the United States and Europe, mold manufacturers such as micro-turning mold and micro-milling and other more advanced technology to maintain their competitive edge.
Small parts machining For small part machining is one of the major challenges mold micro-machining. Die effective area of the direct milling and EDM electrode manufacture of small milling process are made on very high demand.
And micro-milling-related challenges include reduced diameter of 100 microns ( m) or smaller micro-tools to use and operate in up 150,000 r / min of very high speed. Surface quality (Ra) need to 0.2 m. And since for such small parts and tiny details, polishing is unrealistic demands is a micro-milling process without polishing.
Micro-milling technology Micro-milling in order to obtain the required quality and accuracy while meeting economic constraints, the entire manufacturing chain must be optimized and synchronized. CNC Machine tool , Tools, tool holders, jigs and quality control equipment suppliers need to be a competitive cost to provide the right solution.
The following is an environment in the micro-milling should list the main issues raised:
Tool, tool holder and spindle Small size of the tool is achieved by micro-milling. According to the size of the workpiece, which can be as small as 0.1mm, and in the future may become even smaller. In a micro-milling project entrusted to consider the availability and cost cutting tools.
In is when small diameter cutting tools, high-speed spindle is essential. In the spindle 10,000 r / min the tool to use 0.1mm diameter, which means cutting speed (Vc) is only 3.3m/min, which is too low!
Level of 20,000-150,000 for speed spindle, spindle and holder of thermal expansion combined with a totally dynamic balance, zero beating is necessary. Otherwise, it will damage the surface quality and significantly reduce tool life.
Fixtures, clamping systems and manufacturing processes
