145423-aug 2013.pdf
TRANSCRIPT
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August 2013
Volume 16 / Number 8
DesigN / bu ilD / repAir
Raising the Bar on Better
Moldmaking PG 30.
FEATURES
Finding the Right High-Feed
Indexable Milling Tool PG 37.
Inspecting Highly Complex
EDM Projects with Industrial
CT Scanning PG 43.
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PublisherClaude J. Mas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Metalworking Group PublisherTravis J Egan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Editorial DirectorChristina M. Fuges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Senior WriterSherry L. Baranek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Economics EditorBill Wood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Contributing Writer, Special Projects Jan Bottiglieri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Art DirectorCarla M. Turner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Advertising Production ManagerBecky Helton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
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
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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 recommen-dation 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
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2 MoldMaking Technology August 2013
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Great Tips from This Issue5TRICKS OF THE TRADE
Contents
4 MoldMaking Technology August 2013
Features
30 Automation Raising the Bar on Better
Traditionally customized moldmaking to complete automation.
34 Mold MaterialsConsiderations for Mold Base Material Selection
Choosing the right material affects application profitability and cost.
37 Cutting ToolsFinding the Right High-Feed Indexable Milling Tool
The value of versatility and reliability in your high-feed machining solution.
40 Software Are You a Control Freak?
Using simulation to determine the right valve gate sequence.
43 Inspection/MeasurementInspecting Highly Complex EDM Projects with Industrial CT
Scanning
Industrial CT scanning plays an integral role in the EDM process.
46 Mold Maintenance/RepairIn the Trenches
Shaving with Occam's Razor, Part 2.
Departments
6 From the Editor: Mainstream Moldmaking?
6 Whats New on MMT Online: Business Strategies
8 New Business Opportunities: Plasticraft Molds, Inc.
10 Your Business: RTI and On-the-Floor Learning
12 MoldMaking Business Index
14 Profile: Crest Mold
18 Case Study: EDM
22 Case Study: EDM/Machining
27 Case Study: Machining
48 Product Focus
53 MoldMaking Marketplace
54 End Market Report: Aerospace/Defense and Energy/Power Generation
55 Ad Index
56 TIP: EDM
On THE COvER
Image courtesy of Rexam Mold Manufacturing (RMM; Buffalo Grove, IL; rexam.com/mold). This months cover shows RMMs Mega-Cella production system that ties together all available opportunities to automate and control the mold manufacturing process. See feature story and video link on page 30.
Images courtesy of (left to right) Buss Precision Mold, Kennametal and CAE Services.
1. Imagine That When you inject 400 plastic into a 350 mold material fows back into itself on the backside of seal-offs, reinforcement fbers cross link, thin ribs fll without diffculty and minimal wall thicknesses are easily achieved. PG. 14.
2. Roughing It Roughing strategies can be more effective with the correct high-feed milling application, since high feeds and shallow axial depth-of-cut make it possible to produce components to near net shape. PG. 37.
3. Freak Out Being a control freak in the injection molding world isnt such a bad thing when it comes to designing your molds. PG. 40.
4. Back and Forth Industrial CT scanning in EDM helps go from the problem steel back to the process quickly, and accuratelyimproving quality control and reduc-ing costly rework. PG. 43.
5. Keep an Eye on Tension An AWF system that includes a wire tension monitoring device enabling continuous observation is important. PG. 56.
August 2013 Volume 16 / Number 8
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This MonTh on moldmakingtechnology.com
From the Editor
6 MoldMaking Technology August 2013
Mainstream Moldmaking?Will moldmaking in the mainstream help attract a future
generation? Going to the source to get honest answers may help.
Christina M. Fuges
Editorial Director
It continues to amaze me how kids today still dont
find manufacturing exciting; or, is it that weve
just done a very poor job of marketing ourselves.
I strongly believe the latter is the hard truth, and
something which we need to address hard and fast!
I was recently part of a meeting that started off
just wanting to hear from moldmakers about their
needs, and how weand other like-minded orga-
nizationscould do a better job of serving them.
Well, that meeting quickly revealed what you prob-
ably already know: the only thing really on their minds is, What are we
going to do about our nonexistent future skilled workforce?
To me it boils down to the fact that manufacturing as a wholeand mold
manufacturing even more sosuffers from bad PR. Perhaps we arent seeing
any interest because we are not selling ourselves appropriately. I believe we
need to go mainstream to catch the attention of that next generation. So,
what do we do?
There are so many current efforts, and although many are wonderful,
none hit that mainstream mark. Maybe instead of talking amongst ourselves
to find the answers, we need to go right to the source12- to 16-year olds,
a critical age for this type of exposureand ask them what makes them
tick. What motivates them to buy, to engage, to participate, to want to learn
more? Then craft the appropriate marketing campaign to capture the solid
interest of some future mold manufacturers! Lets face it, they cant know if
they like something, if they dont know it existsor what it can do for them
academically, socially, financially, etc.
Below is a very small sampling of some videos. Run them by some 12- to
16- year olds you know, and see what they think.
http://www.youtube.com/watch?v=oQLVT0bfgaU&feature=youtu.be
http://www.youtube.com/watch?v=fTYPrx3RRaI
https://edgefactor.com/edgefactorshow
http://www.youtube.com/watch?feature=player_
embedded&v=IehkopSMnRY
This issue in particular does have some exciting content. Take our
lead story for instanceRaising the Bar on Better (page 30). It takes a
look at moving away from traditionally customized moldmaking toward
a level of complete automation (be sure to check out the video). It really
shows the endless possibilities to thinking outside of the box and effecting
worthwhile change. Oh, and this issue also includes our quarterly Additive
Manufacturing Supplement3D printinga subject that has gone main-
stream and picked up the interest of our kids. Something to think about.
Follow MMT on: Follow @MMTMag
MMT Zone: Leadtime Leader Awardsmoldmakingtechnology.com/zones/business-strategiesTodays mold manufacturer needs to be as much a business-man as a craftsman, so it is crucial to pay attention to the management issues facing your shop includingsales & mar-keting plan, global initiatives/strategies, banking and finance, workforce development and new business opportunities.
Browse Business strategies Zone by Type: Article | Columns | Case Study | Videos | Blog
Understanding the Total Package of the eDM Production Process Is the Key to raising Productivity The best way to determine the training best suited to your company is to find out what your customers need.
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8 MoldMaking Technology August 2013
New Business Opportunities
Wiping the Slate Clean with a Brand-New Facility
By Sherry L. Baranek
In its 22-year history, Plasticraft
Molds, Inc. (Richfield, WI) was
sold to another moldmaker in
2003 and subsequently shut
down before President Eric
Marlow reopened it in 2006. So,
when an overcrowded building
made workflow difficult, Marlow
jumped at the chance to break
ground on a new facility, wipe
the slate clean and have a facil-
ity to form to our business, not
our business to form to a facility.
Plasticraft builds plastic injec-
tion molds for the automotive,
medical, industrial automation
and consumer products mar-
kets. According to Marlow, the
company was operating at more
than full capacity at its previous location. We knew we had to
move into a larger facility, and didnt feel it was advantageous
for us to lease a larger facility, he recalls. We also looked
at purchasing existing facilities. Existing facilities have good
value in this economy, but we werent able to find anything
that fit our business.
Therefore, the company built a facility from the ground
upand left room for expansion, which Marlow anticipates
happening within the next five
years. Marlow worked with a
local commercial builder who
had experience with custom
facilities. He notes the pro-
cess took approximately 14
monthssix months of design
time and eight months of build
time. The new building stands
at 11,000 square feet, more
than double the size the previ-
ous facility occupied at 5,000 square feet.
Marlow has taken full advantage of the extra space, adding
a Milltronics VM25XP 50 taper machine for roughing core
and cavity components and machining mold bases. We saw
the need in that department as we were forced to outsource
this machining last year, he notes, and we had to wait to
purchase it until the move. The new facility boasts a confer-
ence room, three private offices, six semi-private work sta-
tions, and a fully equipped lunch room/kitchen with an out-
door patio. The company also added an Engel 150-ton press
to increase its sampling capacity for larger tools (it already
has an 80-ton press).
The move was both physically and mentally demanding
on the entire Plasticraft team, Marlow notes. After the two-
week transition period, we were operating smoother than we
were at our previous facility, he states. We had some inter-
nal changes that included a change in management (now
we have a core group that manages the work flow), more
employee responsibilities and better scheduling abilities,
which make us far more organized. Everyone stepped up to
the plate and organized their department so the work flows
smoothly to the next department.
Marlow would like that success to continue, and is antici-
pating another expansion within five years. We put our best
work into our tools, and that shows all the way through into
the style and layout of our new upscale facility, he con-
cludes. We have had steady growth since re-starting in 2006.
Our sales have grown 25 to 30 percent annually since then;
and we doubled our sales in 2012. We have to keep a close eye
on costs making sure we can get the most out of everything
while maintaining high quality mold building.
For more iNFormatioN:
Plasticraft Molds, Inc. / (262) 251-6800
[email protected] / plasticraftmolds.com
After the two-week
transition period, we
were operating smoother
than we were at our
previous facility.
Plasticraft Molds, Inc. recently broke ground on a new facilityrather than
fnd an existing facilityto ft its growing business.
Phot
o co
urte
sy o
f Pl
asti
craf
t M
olds
, Inc
.
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Your Business
10 MoldMaking Technology August 2013
By Ryan Pohl
Apprenticeship training is the foundation of any viable skilled
trade. The methods involved in the practice have evolved
through the years, but with respect to the last 75 to 100 years,
apprenticeship has always included some type of classroom
instruction (often called Related Technical Instruction or RTI)
combined with structured on-the-floor learning.
This approach shows respect to the diverse amount of
hands-on experience and the depth of knowledge necessary to
be successful in this industry. There are many different occu-
pations in this industry that can use the apprenticeship system,
but their requirements varya common breakdown of RTI
to Shop Hours is 576 Related Instruction hours to 8,000 Shop
Floor hours. In this article, we will explore some of the essen-
tial elements that are often incorporated into both portions of
a modern apprenticeship program.
First, it should be understood that the RTI and shop floor
experience should follow a somewhat parallel path. For exam-
ple, the early portion of an apprenticeship program should
include the most basic shop floor tasks and the most basic
RTI classes. Depending on whether or not the apprentice has
previous experience from a tech-
nical training school, this often
means covering basic machining
principles during the class time
while at the same time having
the apprentice do something at
the skill level of machine set-ups,
block-squaring or hole-making.
We have to be careful to
not push the apprentice into
advanced machining respon-
sibilities before they are ready.
Though the apprentice may not
admit it, s/he may begin to feel overwhelmed and unprepared
for his/her job. This may impact overall performance and per-
haps even prompt them to quit the program or even their job.
When designing an apprenticeship program, the employer
has a great deal of flexibility. Regarding the RTI, my number
one recommendation is to ensure the classes that the appren-
tice takes are absolutely relevant to their job and career. Today
that means incorporating elements of modern manufactur-
ing in the RTIsuch as classes on everything from Lean
Manufacturing, Problem Solving and Advanced CNC Concepts
to Leadership and Communication. The RTI can be delivered in
many modern ways as well. The employer could decide to have
their local technical school provide the instruction or they could
choose to teach the classes themselves internally. Of course there
are excellent online resources available that more and more com-
panies are incorporating. We will get into more details about the
Related Instruction piece of the program in a future article.
As for the shop floor component of the apprenticeship pro-
gram, again there is tremendous flexibility. This portion of the
program is all about providing the apprentice with hands-on
experience that you, as the employer, will consider important
both in the short-term and in the long-term. The apprentice
should have some exposure to nearly all jobs on the shop floor.
This can include everything from benching/polishing, mold
building and CNC operations to CAD/CAM and welding. Even
if all the apprentice will do primarily is run a CNC machine, it
is still critically important that s/he has exposure to the other
responsibilities on the floor.
In upcoming articles, we will continue to break down the vari-
ous elements of apprenticeship training. In the meantime, it may
be helpful for you to sit with your management team and discuss
how your company is training your employees. Start to make a
list of the necessary job knowledge and skills for each position.
This will help you determine how apprenticeship training can
be used to sustain your workforce in the future.
contRiButoR
Ryan Pohl is President of Expert Tech.
For more inFormation:
Expert tech / (616) 785-5733
[email protected] / expert-technical.com
Regarding the RTI,
my number one recom-
mendation is to ensure
the classes that the
apprentice takes are
absolutely relevant to
their job and career.Ph
oto
cour
tesy
of
Tech
Mol
d an
d C
reat
ive
Tech
nolo
gy.
Finding, training & Retaining EmployeesRTI and On-the-Floor Learning
Part 4 oF a series
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MoldMaking Business Index
12 MoldMaking Technology August 2013
month, and the rate of expansion is
holding steady.
The prices received in the moldmak-
ing sector actually strengthened in June.
The Prices Received sub-index for the
month was 51.7. The upward momen-
tum in the sub-index for Materials Prices
continued abated somewhat in the
second quarter, as the Materials Prices
sub-index came in at 63.7. So materi-
als prices continue to rise, but the rate
of the gains are moderating. Supplier
Delivery Times continue to get just a tad
longer, as this component posted a 52.5
in June. Offshore orders extended their
downward trend to 12 months. The
Exports sub-index was 44.0.
Total MoldMaking Business Index for June 2013: 50.1
Our latest survey of the North American moldmaking indus-
try indicates that overall activity levels held steady in June
when compared with the previous month. The MoldMaking
Business Index for June 2013 is 50.1.The latest index value is
a 0.2-point decrease from the May value of 50.3, and it is a 5.4-
point decrease from the 55.5 value posted in June 2012.
Though our total Index slipped when compared with the
previous month, some of the underlying indicators suggest
that conditions were actually just a bit better. And the fact
that the overall index has held steady throughout the entire
first half of this year is quite encouraging. We are right now
at the point in time when the negative effects of the federal
budget sequester and the increase in the payroll taxes will
have the maximum impact on the economy.
In the second half of this year, the effects of these events
will start to decrease. So the fact that the moldmaking
industry is holding steady in the face of significant head-
winds in the prevailing economic conditions suggests that
this industry will expand rapidly once the overall economy
starts to gain some upward momentum.
The New Orders component registered a surprisingly
good 53.3 in the latest month, which means that the level of
new business was moderately better when compared with
the previous month. The Production sub-index of 52.9 indi-
cates that work levels also increased when compared with
the previous month. The respondents to our survey con-
tinue to report that backlogs are getting shorter, but they
are doing so at a slower pace. The Backlogs sub-index crept
up to 43.8 in June. The Employment component was 53.8,
which means that payrolls were higher for the sixth straight
Our MoldMaking Business Index stayed very close to the 50-line through the frst
half of 2012. The growth rate in the overall U.S. GDP data during this period was an
anemic 1%. It will take a faster rate of economic growth than 1-2% to generate an
increase in spending for capital equipment, which will in turn create demand for
new molds and tooling. The good news is that despite the sluggish growth in the
overall economy, demand for new molds has held steady. This suggests that the
mold industry is poised for robust growth once the overall economy can generate
some sustained upward momentum. This will most likely happen next year. The
residential construction sector has fnally entered a full-fedged recovery, and
the nations employment fgures are starting to improve steadily. Both of these
trends will push household incomes higher, and after a few months this will result
in increased consumer spending. We expect economic growth to register a gain of
2% in 2012, and it will accelerate to greater than 3% in 2013.
Sub-Indices June May Change Direction Rate Trend
New Orders 53.3 53.1 0.2 Growing Faster 6
Production 52.9 52.8 0.1 Growing Faster 6
Backlog 43.8 41.9 1.9 Contracting Slower 14
Employment 53.8 53.8 0.0 Growing Same 6
Exports 44.0 47.2 -3.2 Contracting Faster 12
Supplier Deliveries 52.5 53.2 -0.7 Lengthening Less 18
Material Prices 63.7 61.6 1.9 Increasing More 18
Prices Received 51.7 49.7 2.0 Increasing Decrease 1
Future Business Expectations 65.4 67.4 -2.0 Improving Less 18
MoldMaking Business Index 50.1 50.3 -0.2 Growing Less 2
55
50
45
40
60
1/13
12/12
11/12
10/12
9/12
8/12
7/12
6/12
5/12
4/12
3/12
2/12
1/12
12/11
2/13
MoldMaking Business Index
3/13
4/135/136/13
-
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Profle
14 MoldMaking Technology August 2013
Crest Mold Technology: On the Cutting Edge of R&D
Canadian mold manufacturer Crest Mold Technology
(Windsor, ON) was established in 1987 by Willie Cipkar
still owner and presidentto build high-precision, non-
automotive molds prior to entering the automotive tooling
sector in the mid 90s. Being located in Windsor, it was logi-
cal to pursue a mold business for the auto industry, which he
believed had one of the most voracious appetites for tooling
due to the continuous styling changes of plastic components.
According to Ed Bernard, Crest Molds Manager of Research
and Development, the company has always focused on inno-
vation and advancements that give customers a competi-
tive edge. With over 30,000 square feet of manufacturing
space and 60 highly skilled and motivated employees, Crest
continues to invest in R&D on behalf of our customers best
interests, Bernard comments. Crests designers focus on
adequately robust molds capable of producing certified accu-
rate parts at optimized cycle times; and Crests moldmakers
concentrate on continuous improvement for efficiencies in
processing the various steels and alloys on the latest Makino
and Toshiba machining centers.
Tops in Technology
Developing and applying technologies to benefit customers
makes Crest a creative and dynamic workplace, Bernard notes.
Crest has an alliance with Matsui of Japan and Cinpres of the
United Kingdom for rapid heat cycle molding using cyclic pro-
cess thermodynamics via project-specific mediums.
The companys designers recently spent time in Japan and
have been working with Matsui since 2006 to establish a
technology transfer method that would include the intellec-
tual property costs so that they are invisible to the customer,
according to Bernard. Including Cinpres in the alliance made
perfect sense from the perspective of additional marketing
expertise, an entire distribution network, and an opportunity
to combine technologies like gas press, gas assist, microcel-
lular foaming and water injection, along with rapid heat cycle
molding apparatus solutions, he comments.
Bernard explains that approximately 10 years ago a technolo-
gy was developed in Japan to satisfy rigid environment rules for
recycling painted plastic parts. The rapid heat cycle molding
methods were created to heat a mold cavity to near glass transi-
tion temperature for high gloss appearance (replicating the look
of piano black painted parts on flat screen TVs and monitors)
with rapid cooling (for curing quickly enough to eject the parts
from the mold) being achieved within a competitive production
speed cycle (taking into consideration the absence of painting
cost and environmental impact expenses), he elaborates.
Crest Mold recognized that the same conceptswhich
were developed for high gloss appearancecould be adapted
to improve structural integrity of almost any plastic parts by
producing mold conditions, which would allow plastic mate-
rials to flow longer distances at lower pressure. This would
result in a uniform dispersion of polymer chains and the rein-
forcing fibers intended to improve physical performance and
reduce cost for its customers, Bernard notes.
Crest has been developing design concepts for molds capable
of temperature changes, within a competitive production cycle,
where the mold cavity surface changes from near glass transi-
tion Tg down to cured ejection levels using cyclic process ther-
modynamics. Because petroleum-based plastics have a broader
thermal range for processing than renewable biomaterial plas-
tics, adaptation and acceptance of biomaterials into the market
has not yet occurred, Bernard states. But, initial experiments
with cyclic process thermodynamics and the application of
rapid heat cycle molding technologies have produced samples
of injection molded complex automotive part geometries using
100 percent biomaterial-based polymers, as well as petroleum-
based plastics with as high as 40 percent biomaterial fiber rein-
forcement, in competitive production cycle times.
Uniting with Universities
The company is also currently engaged in ventures with three
major universities for projects including Biocomposites and
Biomaterials Processing and is also initiating research support
with the Microcellular Plastics Manufacturing Laboratory for
automotive light-weighting applications using RHCM surface
enhancement technology.
Once again, the company formed an alliancethis time
with a university for R&D efforts. Personnel from The
Crest Mold innovations make molders more productive.
Phot
o co
urte
sy o
f C
rest
Mol
d Te
chno
logy
.
-
Profle
16 MoldMaking Technology August 2013
For more inFormation:
Crest Mold Technology
(519) 737-1546
crestmold.com
University of Toronto have been working hand in hand with
Crest design staff at the Crest facility. After demonstrating
our technological capabilities to Ford Motor Company, the
improved thermal control aspects were identified as poten-
tially being able to overcome flow issues with an experimen-
tal bio-material that was being developed in cooperation
with the University of Toronto and introductions quickly led
to collaboration.
Continuous stability, even during the recent global down-
turn, is the result of a systematic approach to problem-
solving and a clear focus on innovation, Bernard adds. Crest
designers have also recently discovered that accepted indus-
try processing limitations can be overcome with enhanced
cyclic process thermodynamic control systems, which are
capable of radically changing the boundaries of previous
molding cycle limitations.
Plastic used for injection molding requires high heat to
flow and low heat to cureso pretty much every mold in
production ends up running at a compromised temperature
somewhere between the correct high injection temperature for
filling and the proper low temperature for quick curing and
ejection, Bernard continues. Once the single compromised
temperature is established, its up to the injection pressure to
force the already curing plastic into the cavity details of the
mold, he says. Cresta pioneer of various types of two-short
moldsis now engaged in a systematic investigation of tech-
nology applications and combinations of processes, which
are anticipated to change the paradigm for plastic processing
parameters, especially with emerging applications for biomateri-
als and nanocomposites. Biomaterials typically have a smaller
thermal processing range than their petroleum-based counter-
parts and to make things even more challenging, biomaterials
are characteristically more viscous, so optimized thermal con-
trol in the mold is essential, he adds.
Every plastic parts manufacturer knows what happens when
one tries injecting 400-degree plastic into a 100-degree mold. It
doesnt get very far without numerous gates and lots of injec-
tion pressure. Bernard explains, You end up with non-uniform
densityresulting in warp and distortionas well as flow
marks and knit lines on the backsides of seal-offs. Imagine what
happens when you inject 400-degree plastic into a 350-degree
mold. Material flows back into itself on the backside of seal-offs,
and reinforcement fibers actually cross link, thin ribs fill with-
out difficulty and minimal wall thicknesses are easily achieved.
What you probably didnt imagine was
the phenomenon of a resin-rich surface,
which completely replicates the cavity
surfacewhether bright gloss or matte
textureand which completely buries
the reinforcement fibers.
Focus on the Future
Crest Mold Technology recognizes that
the companys success is dependent upon
making its customers successful. Intense
investigation of technologies that can be
advanced for applications that give our
customers an edge is what Crest Mold
research and development is all about,
Bernard concludes. Working with mold-
ers to produce stronger, lighter weight
parts, using less energy with lower mate-
rial costs, Crest is determined to be the
leader for optimized cycle time with
guaranteed reliable tooling.
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18 MoldMaking Technology August 2013
Case Study / EDM
By Jan Bottiglieri, Contributing Writer, Special Projects
Pushing technology to the edge is standard operating pro-
cedure for NyproMold in Gurnee, IL. Recently Pete Smith,
Group Leader EDM-WEDM-Graphite, explained how the
addition of a new EDM machinethe Mitsubishi MV1200-R
Advance Plushelped the shop reach new heights of effi-
ciency and performance. Im very impressed; its a fun
machine to run, Smith says. Processing speeds are so much
more advanced than even five years ago, and it has made a
big difference for us.
Founded in 1987, NyproMold builds plastic injection molds
for the healthcare, packaging, consumer, and electronics
markets. The company has two facilities: the 35,000-square
foot Gurnee facility boasts the same high-level capabilities as
the larger headquarters facility in Clinton, MA.
More than 50 percent of
the shops work serves the
medical industry, and that
tight-tolerance work is a dif-
ferentiator for the company.
Our facility manufactures
molds ranging from one cav-
ity, all the way up to 128 cavi-
ties or more. We pride our-
selves on being able to quickly
accommodate part changes
from our customerswe can
make a whole new stack of
components, and theyre com-
pletely compatible with the
existing mold frame. The only
way you can do that is if youre able to hold tight tolerances,
Smith explains.
Because Mitsubishis MV series EDM machines feature
the latest technology in auto-threading, internal machine
communication, power supply and operating cost reduction,
it seemed like a great fit with NyproMolds focus on giving
customers high performance. At the 2012 IMTS show, the
company purchased three of the MV1200-R Advance Plus
wire EDM machines: two for the Clinton location and one
for Gurnee.
The MV 1200 Rs non-contact cylindrical drive system
makes it possible to reach a new level of precision, Smith
reports. We can cut pockets and different tapers that a lot
of machines cant cut with conventional machining, he
says. The motors are literally running on magnets, without
the wear issues of running on ball screws, like traditional
machines. It is able to hold a much more precise positioning.
The machines automatic feed adjustment has been anoth-
er huge advantage, says Smith. Any time youre using a wire
EDM, theres a feedback factor. When the wire gets too close
to the material or starts to pull too far away as youre cutting,
your feedrate needs to adjust, he explains. The quicker you
can respond to thatand were talking millisecondsthe
more consistent your cut is going to be, and the faster youll
cut because youre cutting as efficiently as possible. This
machine has changed wire EDM in a way that the machines
Ive operated have not been able to do, because it cuts sub-
stantially faster than its predecessors, yet it consumes about
40 percent less wire.
Down to the Wire
That lower wire consumption, coupled with faster operation
and wire recycling, is a winning equation for Smith. The
Imag
e co
urte
sy o
f N
ypro
Mol
d.
MV1200-R Advance Plus wire EDM.
New EDM Pushes
Performance and
Precision
This machine has
changed wire EDM in a
way that the machines
Ive operated have not
been able to do, because
it cuts substantially faster
than its predecessors,
yet it consumes about
40 percent less wire.
-
20 MoldMaking Technology August 2013
Case Study / EDM
newer machines chop wire instead of just spooling it out like
angel hair, so you get a bit more money back when recycling,
he says. Its not a new technology, but it does make it easier
to handle. We pay about $6/lb. for wire, and our recycling
yields around between $2.85 and $3.15/lb., so were getting
almost half the money back; and by using less wire, the
profitability is going up substantially. I get 50 percent back
by recycling, plus about twice as much work done with the
same amount of wire, and getting it done faster. There are no
negatives there.
Plus, the threading mechanism is far superior to any
other Ive experienced, Smith adds. Anyone who has run a
wire for a long time knows that to get your unattended run-
ning time, the machine needs to thread independently while
youre home in bed. Lets say the part
has 100 holes, when you come in in the
morning, you dont want the machine
to have missed 60 out of 100. You want
it to have threaded every one.
Smith was able to witness the MV
1200 Rs advanced threading system
when he stopped by the shop over a
long weekend to put a new spool of
wire on the unattended machine. The
wire had broken in the middle of a cut.
Normally when that happens it can
be difficult to retrace that path, but
this machine actually rethreaded right
through the cut.
Smith cites the machines high capac-
ity as a deciding factor when selecting
the MV 1200 R. At the time, NyproMold
had taken on some jobs projecting a
very high volume of wire time, and the
new machines helped the company
deliver on time, with great results.
Final Advice
Smith says that just 10 years ago he
There has been a kind of Aha!
moment in the application of tech-
nology. Machine manufacturers
began to look at not only how
were generating the spark, but
also how were responding to the
spark. We were not responding
quickly enough. The result has
been the better threading capability,
the increased processing speed.
I will never doubt again how far
technology can go.
-
moldmakingtechnology.com 21
suspected that EDM technology had gone about as far as it
could. We would joke that its just a 10-thousandth wire,
theres only so much electricity you can put into it. But I
didnt realize how much the computing side of it had been
holding EDM back, he says. I think theres been a kind of
Aha! moment in the application of technology. Machine
manufacturers began to look at not only how were generat-
ing the spark, but also how were responding to the spark. We
were not responding quickly enough. The result has been the
better threading capability, the increased processing speed. I
will never doubt again how far technology can go.
He offers this example. Ive got an EDM machine that we
bought in 2010. We did some time trials and, at the time,
that machine cut about 30 percent faster than our previous
machine, which wed purchased in 2006. That is a pretty big
jump in just four years. Our new Mitsubishi wire EDM cuts
about 30 percent faster than that. The technology basically
obsoleted our 2010 machine. And thats just a two-year peri-
od for the same increase.
Smith says that service is a key factor when buying a new
EDM. Because of the economy, some manufacturers seem
to have made major cuts in their service area. In my opinion,
For more inFormation:
MC Machinery Systems, Inc. / Mitsubishi EDM
630-616-5920 / mitsubishi-world.com
NyproMold / (978) 365-4547
nypromold.com / [email protected]
service is huge. If your machine goes down youre not just
not making money, youre losing money. Mitsubishi does a
great job. They have an outstanding training program.
Finally, Smith recommends that moldmakers shopping
for an EDM look for bang for the buckthat perfect bal-
ance of profitability and accuracy. He concludes, There
are machines out there that might be able to cut with even
higher precision, but they cost three times as much. It really
depends on your shops needs.
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22 MoldMaking Technology August 2013
Case Study / EDM / Machining
GW Plastics (Bethel, VT)a global leader in plastic injection
molding and contract manufacturing offering in-house mold
design and buildwas looking to become more competi-
tive when working on multi-cavity molds and also wanted to
decreased sinker EDM and bench polishing operations. This
set off their search for the right technology solution.
A Rich History of Growth
With its world headquarters located in the picturesque Green
Mountains of Vermont, GW Plastics has built a reputation as
one of the industrys most respected precision injection mold-
ing and contract manufacturing companies. GWs focus is
on injection molding, tooling and contract manufacturing of
precision thermoplastic and silicone assemblies (and compo-
nents) for the healthcare, automotive, consumer and industrial
marketsall these markets being safety critical. GW excels at
close-tolerance mold building, injection molding and contract
assembly with a matrix of competencies geared toward innova-
tive problem solving, Six Sigma quality, speed-to-market and
global manufacturing.
GW Plastics was founded more than a half-century ago
when two early plastics pioneers, John R. Galvin and Odin A.
Westgaard, decided to combine their extensive business and
materials engineering experienceand their initialsto start a
plastics injection molding firm. After building GW into one of
North Americas premier precision injection molders, they sold
the company to Carborundum in 1973. After a series of large-
company M&A transactions in the 1980s, GW ultimately found
itself owned by Standard Oil of Ohio (Sohio). In 1983, a group
of the companys managers and investors led by Frederic Riehl
purchased GW Plastics from Sohio. GW has remained closely-
held, under the same ownership to this day. In 1998, Brenan
Riehl became President and CEO after a successful career with
Owens-Illinois and General Electric assuring a successful lead-
ership transition and continuity of ownership.
The 1990s ushered in a period of rapid growth for GW, driv-
ing significant expansion of the companys manufacturing
capabilities and its geographic reach across the U.S. In 1990,
GW relocated and expanded its moldmaking facility to a new
Technical Campus in Royalton, VT. In 1992, GW expanded
into the Southwest opening a new facility in San Antonio,
TX; followed by a new plant in Tucson, AZ in 1996. GW fur-
ther expanded its Royalton Technical Campus by opening a
Technology Center dedicated to statistical mold qualification
and new technology development in 1997, and by establishing
its Royalton, Vermont Medical Molding facility in 1999.
In 2007, GW expanded globallysimultaneously into
two hemispheresby adding facilities in both Mexico and
China. In 2008, GW announced its entrance into the Liquid
Silicone market with GW Silicones in Royalton, VT. In 2012, in
response to increased demand, GW completed an expansion of
its GW Silicones operation at its Royalton, VT location.
With eight facilities operating from six locations worldwide,
equipped with six class 8 cleanroom molding and assembly
areas, GW has grown to a combined 350,000 square feet of
environmentally-controlled injection molding, tooling and
contract manufacturing space supplying market leading OEMs
across the globe.
GW invests heavily in both salaried and hourly workforce
training with a focus on quality to ensure its associates are
trained in the latest technology and manufacturing tech-
niques. GW accomplishes this through an in-house apprentice
program and classroom training in partnership with local tech-
nical colleges to ensure an adequate supply of skilled personnel
to support its growing needs.
GW is, consequently, seen as a preferred local and industry
employer with a motivated workforce and exceptionally low
turnover. Among senior management, the average term of
employment is 20 years, salaried employees have an average
tenure of 13 years, and hourly employees average eight years
(a remarkable hourly seniority for a 24 x 7 manufacturer). GW
currently has a large number of hourly and salaried employees
with service between 20 and 50 years.
Imag
es c
ou
rtes
y o
f S
od
ick
and
GW
Pla
stic
s.
Mike Ryon, EDM Specialist at GW Plastics with the Sodick AG60L sinker EDM,
which has an X, Y, Z travel of 23.62 x 16.54 x 14.57 (600 x 420 x 370 mm) and
can accommodate workpieces up to 3,307 lbs (1,500 kg). This sinker EDM is also
linear motor driven and comes with a 10-year positioning accuracy guarantee.
Traditional Labor
Values Meet
Linear Technology
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-
24 MoldMaking Technology August 2013
Case Study / EDM / Machining
Technology Investment Proves Successful
GW realized in 2007 that they needed to improve their time
frame from which they could bring a product to the market
from the initial concept/design stage. They knew that speed to
market was critical. They needed to purchase new, high tech-
nology machines to do so. GW was also looking to cultivate/
train its labor force along the way.
GW evaluated its machining options, and decided that Sodick
machines were the way to go to meet their goals. GW Plastics is
committed to continuously investing in precision tooling tech-
nology, states Timothy Holmes, GW Plastics VP of Engineering.
Over the past few years we have purchased a Sodick wire
EDM, sinker EDM and high-speed mill, he goes on to say. In
2010 GW first purchased the linear motor driven AG600L wire
EDM and a few months later added the
linear motor driven AG60L sinker EDM.
They then added the linear motor driven
HS650L high-speed mill in 2011. In 2012
GW decided to add an additional AG60L
sinker EDM and integrate a System 3R
Robot between the two sinkers.
The AG600L has an X, Y, Z travel of
23.62 x 15.75 x 13.78 (600 x 400 x 350
mm) and can accommodate a workpiece
up to 2,204 lbs (1,000 kg). This wire EDM
features linear technology and has a
10-year positioning accuracy guarantee.
The AG60L has an X, Y, Z travel of 23.62
x 16.54 x 14.57 (600 x 420 x 370 mm)
and can accommodate workpieces up to
3,307 lbs (1,500 kg). This sinker EDM is
also linear motor driven and comes with
a 10-year positioning accuracy guarantee.
The HS650L is Sodicks high-speed
mill that has linear motor drives and a
40,000 rpm spindle. The X, Y, Z travel is
24.41 x 19.69 x 11.81 (620 x 500 x 300
mm) and has a rapid feedrate of 1,417
ipm (36 m/min).
What GW gained was high reliability,
improved speed/throughput without
sacrificing accuracy or quality and a high
level of satisfaction from the operators,
Jim Comette, CNC Specialist at GW Plastics with
the Sodick HS650L high-speed mill, which has linear
motor drives and a 40,000 rpm spindle. The X, Y, Z
travel is 24.41 x 19.69 x 11.81 (620 x 500 x 300
mm) and has a rapid feedrate of 1,417 ipm (36 m/min).
-
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26 MoldMaking Technology August 2013
Case Study / EDM / Machining
For more inFormation:
Sodick / (847) 310-9000 / sodick.com
GW Plastics, Inc.
(802) 234-9941 / gwplastics.com
on all the machines. GWs technicians enjoy the friendly control,
reliable threading and decreased maintenance.
This Sodick equipment has increased our throughput and
machining accuracy, which is crucial to meeting speed-to-mar-
ket requirements for the tight tolerance precision thermoplas-
tic and silicone injection molds that we manufacture. The new
equipment in our Royalton, VT Mold Division, in conjunction
with our adjacent Technology Center where we immediately
begin the GW Plastics scientific molding process development
phase, provides us with a significant competitive advantage for
new program launches, stated Holmes.
GW was very impressed with Sodick Product Manager, Tom
Hipp. While at IMTS a GW staff member saw the demonstra-
tion on the HS650L and was impressed with the surface finish
that was achieved. He requested Hipp to
come in for a follow up visit, after the
IMTS 2012 show in Chicago.
With a strong engineering back-
ground, Hipp was able to optimize
their program to even further improve
their surface finish during his visit to
GW. GW wanted to achieve a 10.6
micro inches Ra surface finish on the
HS650L, states Hipp. I went in and
improved the process to achieve the
requested surface finish and within a
few hours they were up and running
with their desired surface finish. They
just needed a few tweaks with the CAD/
CAM program they were running to
reach the full potential of the HS650L,
Hipp adds.
GW has now become more competi-
tive working on multi-cavity molds due
to their two Sodick sinker EDMs and
System 3R Robot; while the purchase of
the Sodick HS650L high-speed mill has
greatly decreased their sinker EDM and
bench polishing operations.
They were also happy with the
seamless installation, training and
implementation that Sodick offered.
Sodick Engineers were on hand to get
the machines installed right away, and
offered training so GW was up and
running in no time. GW states that the
cultural fit between the two compa-
nies made the process of installation
and implementation much easier than
expected.
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Case Study / Machining
moldmakingtechnology.com 27
Case Study / Machining
Manpower, Machine Time Maximized with
Highly Accurate VMC
moldmakingtechnology.com 27
By Sherry L. Baranek
Buss Precision Mold Inc. (BPM; Clackamas, OR) may be small
in number with 10 employees, but possesses the technology
namely a DMC 105V Linear VMC from DMG/Mori Seiki USA,
Inc. (Hoffman Estates, IL)of a larger shop to tackle molds up
to 36 x 48. This includes collapsible core, unscrewing, over-
molding tools and complex action designs needing extremely
high accuracy across the entire machining envelope. It was
for these reasons the company sought a machine with a larger
work envelope without sacrificing accuracy.
According to BPM President Jonathan Buss, tolerances and
finishes on the companys molds are tailored to the specific
project, but most work is held to +/-.0002 tolerance on multi-
cavity components, cavity, cores and parting lines. Thus, BPM
needed a larger capacity machine that would provide the
tolerances required as well as allow through-spindle coolant
for drilling operationsfor deep holes, which are required for
ejector pins, cap screws, waterlines and other mold compo-
nents through thick plates and also allows spindle orientation
for tapping routines. Plus, if the
machine had through-spindle
coolant capabilities, BPM would
not have to change machines to
drill different holes.
Thus, when BPM began a
search at IMTS for a high-
speed milling machine with a
larger size capacity, through-
spindle coolant capabilities
were a requirement. I gathered
information from prospective
builders, reviewed their offer-
ings and then picked several to
see in person at IMTS, Buss
recalls. We had high-speed machining centers, but we could
not drill or tap holes on them. We wanted a machine with the
additional solution of through-spindle coolant and tapping
on a 18K spindle.
Conquering Challenges
Buss decided upon the 105V for its larger machining enve-
lope (due to the portal or bridge construction), linear drives,
glass scales and through-spindle coolant capability with an
18K-RPM spindle for drillingas well as millingon the
same machine. Most high-speed milling machines do not
offer through-spindle coolant for drilling ejector pin holes,
or thread milling so they must be moved to another machine
for that process, he notes. We can eliminate a step in the
manufacturing process for pre-hard steel molds. Buss adds
the machine work envelope access is superior to most vertical
machines of any configuration, allowing unrestricted access
to two sides of the machine table.
DMG/Mori Seiki USA Executive VP Randy Harland points
out that this machine does extremely well in mold shops
for the reasons Buss outlines above. The construction of the
machine, its rigid bridge-type design, and the control tech-
nology give the 105V a unique advantage in milling of mold
cores and cavities, he says.
The machine also yielded improved surface finish. The
linear motors produced a noticeable surface finish advantage
of the ball screw machines, Buss elaborates. We have run the
same exact program, cutting tools, steel material and machin-
A 12-foot long compression mold for continuous molding of a rubber
conveyor belt.
Using highly accurate
machines allows more
effcient utilization of
manpower and machine
timesaving time and
money for the customer
and making BPM more
proftable.
Video
Access video
at end of article.
Pho
tos
cour
tesy
of
Bus
s P
reci
sio
n M
old
Inc
.
-
28 MoldMaking Technology August 2013
Case Study / Machining
ing parameters on the ball screw machines, and the results are
very impressive. The improved surface finish requires less pol-
ishing when specifications such as texturing or mirror finishes
are required.
Furthermore, the DMG linear drives are extremely accu-
rate, without any axis reversal errors, Buss continues. In
recent ball bar runs, the technician thought his testing unit
was malfunctioning as he had never seen a machine test so
accurately on a round test pattern, he explains. He had to
make the program out of round to confirm it was actually
following the prescribed path, and once he saw the change in
test data, reverted back to the original programconfirming
his initial testing. He stated numerous times he had never
seen a machine so accurate.
Expanded Work, Uninterrupted
Buss is satisfied with the way the 105V has allowed BPM to
take on the building of larger molds, or allow multiple work-
pieces to be setup and run without interruption. One of our
first jobs that utilized the extra machine travel and accuracy
on the DMG was a 12-foot long mold for molding continu-
ous conveyor belt sidewalls, Buss recalls. It was made up Shop Manager Joe King fnish milling on the DMG DMC 105V Linear.
-
moldmakingtechnology.com 29
For more inFormation:
DMG/Mori Seiki USA, Inc. / (847) 593-5400 / moriseikius.com
Buss Precision Mold Inc. / (503) 652-5804
[email protected] / bussprecisionmold.com
Haimer-USA / haimer-usa.com
Lyndex-Nikken Inc. / lyndexnikken.com
OSG Tap & Die Inc. / osgtool.com
Video: mold roughing http://short.moldmakingtechnology.com/bussrough
of four 3-foot sections. We would not have previously taken
on a project of this size without the added travel of the
machine.
Additionally, Buss points out that these machines have
allowed his moldmakers to concentrate on getting their
jobs done, instead of chasing around machining tolerance
or thermal growth errors. And, the company has reduced
leadtimes significantly over when it was using conventional
machinery. Buss says it is hard to measure the leadtime
reduction definitively as workpieces vary. However, he says in
some cases the company has spent less time polishing com-
pleted molding surfacesat times up to 50 percent.
Keith Foster, Account Manager at DMG/Mori Seiki dealer
Ellison Technologies (Grand Rapids, MI), adds, Our DMG/
Mori Seiki customers that utilize DMG high-speed linear
technology have seen great improvements in mold contour-
ing accuracy and surface finish qualityall with a reduced
cycle time. Another benefit often overlooked is that they get
longer cutting tool life, which helps reduce cutting tool costs
for their jobs.
Using high accuracy milling toolslike OSG cutters and
Haimer or Lyndex/Nikken toolholders on the DMGallows us
to take advantage of the accuracies and speed of the machine
for a complete process, Buss concludes. Using highly accu-
rate machines allows more efficient utilization of manpower
and machine timesaving time and money for the customer
and making BPM more profitable.
-
Automation
30 MoldMaking Technology August 2013
By Jan Bottiglieri, Contributing Writer, Special Projects
Raising the Bar on Better
Moldmakers love the idea of better. Most continually
ask the same two questions: (1) How can we build
this better, more quickly, more efficiently, with less
cost and effort? and (2) How can we build a better one?
For Len Graham, Business Unit Leader at Rexam Mold
Manufacturing (RMM) in Buffalo Grove, IL, the question of
better doesnt stop with the single part produced or with the
steps taken to produce it. After 46 years in the moldmaking
industry, he is working to create a new way of approaching
the entire process: its called the Mega Cell.
Graham and his team are collaborating with companies
including System 3R, Mitsubishi EDM, Solidworks, Delcam
and GF AgieCharmilles, along with RMMs dedicated team, to
turn his revolutionary idea of better into a functioning reality.
At the heart of the project is a desire to move away from
a traditionally customized approach to moldmaking, and
toward a level of complete automation that raises the bar
on accuracy, repeatability and control. A manufacturing
A look at one project to move away from traditionally customized
moldmaking toward a level of complete automation that raises
the bar on accuracy, repeatability and control.
unit cannot effectively process the same thing being done
multiple waysalthough this is the norm for moldmaking as
we all learned it, Graham explains. Each craftsman would
create an end product by working on it in his own preferred
way, but an automated system will freeze, or at least drasti-
cally lose efficiency, if it is fed work in that way.
In contrast, the Mega-Cell is a production system that ties
together all available opportunities to automate and control
the process. In doing this, enormous dividends are being
paid not only within the more automated areas, particularly
the Mega-Cell, but in all areas operating. Far fewer mistakes
are made, and with strict first article inspection, any errors
are found immediately and thus corrected at very low cost
on whole.
Imag
es c
ourt
esy
of R
MM
.
The Mega-Cell is a production system that ties together all available
opportunities to automate and control the process.
Video
Access video
at end of article.
-
moldmakingtechnology.com 31
Beyond Super
The Mega-Cell has its roots in a project Graham began about
a decade ago, working as Director of Tooling/Engineering
with Tech Groups C/EC Division in Scottsdale, AZ, on what
was then called the Super-Cell. While that project generated
a lot of industry interest, it never quite reached completion
before the company was sold; the technology available at the
time had not caught up with the idea.
The same companies that originally supported that project
are on board for the Mega-Cell. We have a lot more bullets
for our gun this time, Graham says. The idea can be viewed
as a process patenta way to do something unique. This
version is a variation of that process, but updated to the tech-
nology available today.
When complete in about five to six years, the Mega-Cell
will be the worlds first fully automated mold manufacturing
system. It will consist of two automated manufacturing
systems: a rail system on one side of the shop for manufac-
turing mold inserts, and machining centers and a larger-
capacity rail system on the other side for manufacturing
mold plates.
The mold insert manufacturing rail system will have
five rails, each approximately 30 feet long; each will have
one robot feeding five or six pieces of equipment. Each rail
will have a CMM to verify and track all critical-to-function
dimensions on pallet-mounted mold components and elec-
trodes, and all machining disciplines needed to manufacture
these components will be represented on the lineplans
include high-speed machining centers, jig grinders, surface
grinders, laser engravers, and more, all robot-ready.
Component carousels will pass components from one rail
to another and back again as required to keep all machines
operating efficiently. Rotary carousels and bookshelves are
in place to carry small, medium and larger sized mold com-
ponents. The robot can automatically change arms/hands to
facilitate changing different style pallets to carry the compo-
nents. Pallet sizes range from 2 1/8 sq. in. (the smallest) to 12
sq. in. (the largest).
Smaller pallets go into the machines on a robot switch-arm
that can take one pallet in and remove one from the machine
in one trip. Each pallet includes an embedded radio-frequen-
cy (RF) chip; a technician scans the chip, identifies the piece
on the pallet, and assigns the machining programs/work
being done to it for processing and inspecting. The center of
all design, programming, manufacturing, and inspection is
a pallet-mounted high-precision gage ball. Each component
has a single point of reference that is consistent with all
machines and inspection associated with it on the line.
After the mold insert/electrode manufacturing unit is
complete on one side of the shop, it goes to the other side,
where there will be horizontal machining centers and a larger
capacity rail system for manufacturing the mold plates for
the mold bases. This system will use the same auto-locating
feature as the mold insert manufacturing unit, with the pal-
letized gage ball.
The idea in both scenarios is to be able to place a work-
piece into a machine robotically and begin machining and
inspecting without the need to use probing or some other
ancillary means of finding it before machining/inspecting can
begin, Graham explains.
We simply use the solid models of the components associ-
ated to the component receivers/holders. All mold plates will
join the mold components on the same end of the shop for
assembly on the benches. Assembly benches are just outside
the mold sampling room, so that everything moves in one
direction until becoming a completed, sampled and shipped
mold tool.
Customers and Collaborators
The Mega-Cell is monitored with cameras and machine con-
trols provide Internet access; this allows customers to see
LeArn MoreVisit our Automation and Machining Zones for more information
on a variety of machining technologies including milling, grinding,
boring, drilling, as well as automation solutions.
Go to moldmakingtechnology.com/zones for a complete list.
When complete in about fve to six years, the Mega-Cell will be the worlds
frst fully automated mold manufacturing system. Here is a System 3R robot
working in the cell.
-
Automation
32 MoldMaking Technology August 2013
and monitor the work being done on their mold components,
and to view inspection reports for every detail as long as
their work remains in the machines. Customers have always
wanted three main things from their moldmakers: molds
built with the lowest practical cost, delivered sooner and of
the highest qualitymost consistent across all dimensions
for all cavities achievable, Graham says. The Mega-Cell can
run 24/7; it runs much of the time untended, without labor
cost; and consistency is the operative word, as it will do the
same thing, the same way, throughout an entire series of
parts, without varying the process. Of course the cost savings
is the last to be realized due to the high cost of development
and the time needed to fully realize the benefit, both in time
and dollars, of the investment.
Fortunately, when Graham arrived at Rexam almost 18
months ago, he found a team ready and willing to make
that investment. I told them that if we were going to do
this, I would need them to work very hard to fill in the
For more inFormation:
Rexam Mold Manufacturing / (978) 906-1127
rexam.com/mold / [email protected]
Video: mega-Cell: moldmaking automation http://short.moldmakingtechnology.com/megacell
RMM Business Unit Leader Len Graham observes Mega-Cell Technician Kris
Sampson as he scans RF (radio frequency) chips affxed to pallets for identifying
work being processed into the Mega-Cell automated production system.
wide technology and systemic gaps, since this would be
the first of its kind. This team has far exceeded my wildest
expectations.
The most difficult aspect of the transformation from an
old-style mold shop into a fully automated mold manufactur-
ing unit is developing the complete standardization that is
necessary for success. During the year prior to installing Rail
#1, each area of discipline (moldmakers, EDM specialists,
CNC machinists and programmers, mold designers, grinding
specialists and tooling engineers) held weekly continuous
improvement meetings to establish one preferred way of
performing every single task. Teams set standards for every
operation strategy for every area, as well as for every opera-
tion or duty.
Standards/procedures manuals are being developed for
every department; no one can work in the area without
reading and understanding the content of the manual, says
Graham.
The RMM team is not the only group on board with the
Mega-Cells potential. Something this exciting draws the
major players like flies, Graham reports. Everyone wants
to be associated with this project as it is poised to move
American mold manufacturing into and even beyond the
world-recognized, high quality arena that is widely known
to exist in Europe. Mega-Cell partners represent all the tech-
nologically advanced manufacturing countries in the world.
We will be happy to be able to say, Hey, we have an advanced
system that gives us the ability to engineer and build a pretty
darn great mold here in the U.S. too.
The customers have set the bar and it is up to us to clear
it, he concludes. I am not talking about RMM alone, but
mold manufacturing on the whole. In the not-so-distant
future, if a mold shop of stature does not make the transition
away from custom moldmaking to systematic mold manufac-
turing, there cant be much room for growthand that shops
survival will come into question, if they try to compete at
this high a level.
-
Mold Materials
34 MoldMaking Technology August 2013
By Paul Britton
Material used for mold bases is pretty straightforward.
The materials are common and have been around for
a long time; however, choosing the right material will
help save time and money. Generally, mold base material can
be broken down into three categories: hot rolled steel, chrome-
moly materials and stainless steel.
Hot rolled steel materials vary from low carbon steel
(A-36 or 1020) up to medium carbon steel (1045 or 1050).
These steels are easy to machine and have reasonable tensile
strength. They are easy to find and are very cost-friendly.
They are usually chosen when the customer has very low
production runs associated with the project.
Chrome-moly materials range from 4130, P20, 4140,
etc., have a hardness range from 28-34 HRC and have good
mechanical properties. They are ideal for cavity and core plates
as well as other plates required in the mold base. They can be
machined fairly well; how-
ever, in some cases with heavy
machining or grinding, a
need to stress relieve the
material may be required.
Stainless steel (a modified
420 F material that is used
for holder block applications)
is pre-hardened to 30-35
HRC. It offers good corrosion
resistance and has very good
machinability. The material is very stable and does not require
stress relieving. In applications where humidity is a problem or
corrosive material is being used this material works well.
Today there are two additional mold base materials to con-
sider. The first material falls in the stainless steel category
(see Chart 1). It is an improved 420 F material currently compet-
ing with 1.2085 in Europe. It has excellent machining qualities
and does not need to be stress relieved. By lowering the carbon
and chrome content, this material has improved machinability,
and has 10 to 15 percent better thermal conductivity than the
420 F material currently being used (see Charts 2, 3).
Choosing the right material can greatly affect
the profitability and cost of your application. Photo courtesy of International Mold Steel, Inc.
Two more mold base