The challenge brief introduction of mould date of delivery

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In metallic treatment industry, bear in that way like mould factory without other plant almost very great pressure. The competition that comes from abroad is intense with each passing day, a few abroad moulds make a manufacturer can compare American person of the same trade to call an inferior value not only, and often can use shorter time consign product. Nevertheless a lot of mould factories of the United States are striking back in directly and gain a victory, high speed cutting (HSM) is they are used maintain, even one of the most powerful weapons of recover position; HSM makes they can throw whole production process a few weeks. The technology becomes HSM greatly is treatment spare parts is brand-new way, its collect of a variety of technologies become greatly, it is the simple union of high speed main shaft and fast and accurate feed on the machine tool not just of course. To support such machine tool, the processing factory must build another kind " become greatly " , necessary new function and an organic whole of indispensable new skill assemble. In the meantime, of the factory " mental culture " also must produce simple change with corporeal facilities. Of course a kind of step that HSM just achieves a goal, shorten the consign cycle of the product and reduce cost and character, HSM can produce effect and very valuable. Any plants that seek HSM should be passed cogitative, all periodic to producing spot inside and outside to be able to accelerate production technologies give take seriously. Successful HSM does not have detailed recipe or hang definitely, because HSM still is in,develop ceaselessly. Almost the factory of each executive HSM can tell you, they still are being improved, still experimenting, still learning, and often review from the middle school of mistake and failure. Executive HSM does not have exclusive and right way, how ought to every kinds of circumstance apply HSM to also be done not have strict and changeless or the criterion of get effect instantly. Notable is, HSM is not theory or the idea that have lab ability test and verify only after all, however practical technology. Factory of 10 several moulds uses HSM now, more hundreds factory is in vigorous effort ground to prepare to carry out. The general situation of the factory that the article is engaged in HSM with a few with great concentration will clarify this kind of situation, the HSM of real world is such. Graph 1: Want fluctuation foreword rationalize only, HSM is had reduce cost and shorten substantially the tremendous potential of consign cycle. The Minnesota Mold of Vadnais Heights of Minnesota of mould of the 5 consign inside week&Engineering or Minnmold company (the email address that uses this firm) the mould that is a 65 people designs a production company, HSM is very important to this company, but more important than HSM is high speed mould is made. People may be right the requirement of interval of rate of main shaft speed, feed, contrail and cutting force is talked about unceasingly, but with Minnmold leisurely relevant is in 5 weeks inside finish mixed pattern, big batch production uses note model or Die CastingA kind mould, normally one come 4 antrum, weight can be amounted to 10, 000 pounds, working limits arrives from the mobile phone wheelhouse and even larger part. In Minnmold, evaluation HSM must be made with high speed mould for premise. To sum up in a word of general manager Bob Archambault: "We are compact, compact again compact. " it is machining not simply, all jobs must achieve highest efficiency. Unless get on those who support HSM, downstream working procedure is straightened entirely and simplify, otherwise HSM impossible be successful or the effect is not big. Mr Archambault HSM praise solicit on current and fatigued and weak mould market for our company the main factor of business. The economy that have the aid of produces at HSM place, this company can pass lower quoted price to win order form, and score more gain as a result of the addition of portfolio; The photograph before using HSM together is compared, machine the mould of 30% every year more. Additional, this company added the employee with adept technology, 18000 square foot extend project last year spring break earth. Graph 2: Machine speed to catch up with faster EDM, minnmold company converts high speed milling machine machines black lead, the main shaft speed of this Roku-Roku GR655 is amounted to 15, 000rpm, electrode needs grinding or polish again scarcely. The bottleneck that electrode produces and a lot of mould plants are same, minnmold involves HSM to enlarge EDM process capability at first. At the beginning of 1995, the machine that a punch of new setup replaces than it is sharp 40% , hold busy position to allow this new machine, minnmold must accelerate the manufacturing rate of black lead electrode. Minnmold at that time milling machine of high speed of black lead of with a view to, but discovery among them of method of cutting tool of a milling machine build the programming that can give a company the branch causes bottleneck, and file of corresponding cutting tool method is particularly long, cannot download the DNC network of the company effectively, then, the company must undertake upgrading to process designing software and communication network, just bought milling machine of Chinese ink of the first socle. Installed 15000 Rpm of speed of a the largest main shaft, quick horizontal stroke to enter the Makino SNC64 of 630 Ipm in those day, buy milling machine of one socle Chinese ink from Roku-Roku again additionally, fill the inadequacy of ability of milling of black lead electrode. The experience of electrode of black lead of high speed milling makes Minnmold company acquire steel of a cutting high speed machine tool, this VM5 that comes from OKK machine tool reachs the designated position at was being installed Summer 1998, every oil that this company place produces today is set forcedly piece going up to use this OKK machine tool to had been machined somehow. Where is the starting point that drives success of HSM of a good head? Minnmold from the client model the 3D hypostatic model that model or Die Casting model must build begins. A lot of clients can provide 3D hypostatic model, but encounter the client that cannot build a model quite, minnmold always is basis 2D or planar information (like blueprint) acting client builds 3D model. Say according to advanced stylist Brian Bussmann, leaving a measure is a whole pattern that includes requirement of all public errand and detail to be designed inside database of CAD of model of substance of design building 3D. Each feature that the pattern buys outside blame is reflected in this database, if every dimension and public errand are tagged. Just as Mr Bussmann points out, "Effective design ability manipulates special key to high speed cutting and even each follow-up, (Mould) design must reasonable, and must quick. " the member that this company has 6 full-time to design, among them 2 people basically design software contact with with the ProEngineer of Parametric Technologies company, the design member of the others basically uses the CADKEY 98 of Baystate Technologies company. The design member of Minnmold company completes mould design according to the 3D model of client spare parts. The 3D database that includes design of complete set detail and noncombatant duty is very useful, every part that makes because of this company must accord with design and tolerancepublic errand requirement: The tolerancepublic errand control of crucial part is in 0.

Inside 0001 inches limits. Mr Archambault explains, "We are machined according to the database, there is the spare parts of the spare parts inside the workshop, because we hope the client can come back to machine refill-unit or be repaired,set piece etc, and everything what we should make calls the data in archives namely and machine new part afresh, the dimension of new part and public errand and original part a bit are not poor. Client simply loads new part, the mould can be used at production afresh. " mould design finishs the file server that refers a company as archives, for our company every PC of computer network is visited (the company of 65 employee has 30 PC) , written presswork the data already made unusual thing. Anyhow, the mould that place of the member that design finishs designs the thing that just wants place to make to come down surely, and must not make certainly. It is to call together next all be about to participate in mould treatment and constructional staff to attend a meeting, be in this " bully ceremony " on, the member that design, process designing member be opposite with tool maker design project " judge a head to talk sufficient " decide cutting is politic. For example, they should use what cutting tool, need certainly every how many electrode, working procedure is occupied about how long and need to consider what chance on plan arrangement, decide what working procedure wants to use HSM and EDM even. The issue that above of fast process designing designs about the mould also applies to programming, chief inspector Mike Myers points out the programming of Minnmold company, fast process designing is very important. The finishing time of task of each process designing has exact plan, with job shops the plan of each working procedure is euqally exact. Be in Minnmold company, programming is the business that does not separate day and night, day shift has 5 programmer, among them 2 full-time at 2D project, 3 full-time at 3D, the controller of ministry of adscititious process designing temporarily fill a vacancy, where to need, appropriative dispatcher and programming ministry and the member that machine the contact between the spot. Still have two programmer besides (2D, 3D each one person) go up continuously every week 5 evening shift. At present programming is finished on the PC, all programmer can apply the CAM software MasterCAM of newest version of CNC software company adroitly, masterCAM offers a lot of utility program that conduce to HSM, be like " speed cutting (High Feed Machining) " . This one function includes Minnmold to often be used " much model face rough machining " and " much model face finish machining " option. Still installed WorkNC of software of CAM of milling of 2 of Sescoi USA company automatic 3D recently. Say commonly, rough machining can be withheld to finish machining 0.

02 inches surplus. Rough machining of milling cutter of head of 1 inch of balls is used on OKK machine tool when, use feed speed 120 Ipm and main shaft rotate speed normally 3500 ～ 4000 Rpm. Say according to Mr Myers, cutting deepness is commonly 0.

05 inches (the 10 % that recommends a value to be cutting tool diameter, but the effect ideal) that this company discovers to so big cutting deepness is inferior to shallow cutting. The basis treats the geometrical form that processes work, often also use round tip pivot to provide, because edge radius is smaller,round nevertheless tip pivot is provided, need uses more shallow cutting deepness. The programming of HSM finish machining is more complex, the variable that because involve,arrives is some more, very difficult treat as the same. The surface that feed quantity inspects work place to ask is bright and clean spend and decide, using a diameter bigger (0.

750 ～ 1.

00 inches) when ball head milling cutter, cutting quantity is 0.

010 ～ 0.

015 inches; Small cutting tool (small to 1/16 inch) it is 0.

002 ～ 0.

004 inches. Because the limit of main shaft speed of OKK machine tool is 8000 Rpm, so feed speed is 120 ～ 180 Ipm commonly, size and cutting load are concerned (commonly used value is every tine 0.

004 or 0.

005 inches of) . Black lead milling is used to using bolder cutting amount, but in in principle it is identical. Anyway, exact numerical value uses formula to reach, the change that these formula reflected luminosity of dimension of workpiece material, hardness, cutting tool, surface to ask to wait for an element reachs his to combine. The formula that this company uses a supplier to recommend and improve through was being carried out. Programmer is unified use same formula, in order to assure the consistency of process designing result. Mr Myers believes, every factory is responsible the HSM complete standard that establishs oneself according to experience. Finally is method of school nucleus cutting tool, use MasterCAM software to emulate the movement of cutting cutting tool on the hypostatic model of workpiece namely; Only simple 2D procedure does not pass examine and verify. Complete or the file server that inputs a company through affirmed order. Factory network HSM asks the factory has appropriate infrastructure, among them a main component is supportive high speed long file of method of deferent cutting tool and the computer network that other communication needs. The network of Minnmold company is based on server of file of Dell PowerEdge 6300, this server passes the PC photograph of optical fibre cable and entire company to join, carry network of figure of ISDN(integrated business) with Internet(internet) join, in order to facilitate high speed is accessed. FTP(file transmits an agreement) join with all PCs, on the network that makes data is in entire company " fictitious bos is broken " flow. The download of long file of cutting tool method already fast reliable, although a few workstation are the same as nowadays,carry same also. The CNC system of machine tool of high speed cutting contains hard disk driver, because this is OK,access whole process with this machine memory. The advanced stylist Brian Bussmann of Minnmold ever helped the network norms that affirmatory company place needs, he mentions file server / of the network build have another kind of value, always be the same as the information that some job or project concern, entirely uses the in an orderly way, means that accesses easily to deposit in same a central database address, he says: "Everybody can find the information that he wants: The member that design can access spare parts model, the member that detail is designed and programmer can access a mould to design a file, the tool of the workshop makes personnel can visit file of cutting tool method. " graph 3: High speed cutting is opposite at least Bill Lobin(is left) with Bob Archambault it is fun, they are checking a part on Okk VM5 machine tool, this machine tool agrees with with speed of tall main shaft (the biggest 8000 Rpm) and tall when to speed (the 400ipm) when cutting processes steel. Cutting cutting tool chooses cutting tool and character, the course of action of Minnmold company is accorded with " cutting tool is politic " the guideline of a series of books. The HSM cutting tool of this company is supplied alone by his tool room and safeguard, buy the advanced steeliness knife handle that passes dynamic balancing only. Every change cutting tool, should be in the radial of cutting tool of nucleus of machine tool captain beats and coaxial is spent. Anyhow, the method that follows standardization on cutting cutting tool is crucial to the success of HSM. However, chief Bill Carter advocates CNC craft to experiment and fumble. He says: "We try everything: New-style coating, novel mold insert and new-style clamping apparatus. " this company made interesting effective black lead milling is politic: Use a standard not to have milling cutter of head of ball of horniness of coating fine grain, these cutting tool are cheaper than special coating cutting tool, and Yi Cai is bought. Minnmold of cutting tool of new generation steeliness is to purchase milling machine of high speed of the 2nd OKK next, milling machine of this KCV600/15L 50 taper, 13000 Rpm of speed of the largest main shaft, the journey 30 × 60 inches, enough uses HSM technology to the treatment of mould base. Milling of new technology high speed can machine complex form face very glossily, perhaps need precision work again far from almost. Gao Guangjie is spent is to pass many shallow cutting and close orbit interval to obtain, the meeting point of tangency that makes round tip pivot provides place to form is the smallest. On one hand, it is OK to increase main shaft rotate speed measure to effective cutting in appropriate cutting force make known to lower levels, increase feed speed to be able to avoid needless handling time on the other hand. Dimension precision is given by the other Electromechanical function of the servo of tall sensitivity and special milling machine assure. Below the case that need not have process of follow-up precision work, the appearance that produces to place of high speed cutting tries to protect the regulation that can ensure the geometrical dimension of workpiece accords with spare parts database from beginning to end. CNC Milling CNC Machining