There are various methods for mold processing, each with its unique characteristics and applications. Here are some of the main mold processing methods:
Machining
Definition: Machining, also known as traditional cutting and grinding, is an indispensable and important processing method in mold manufacturing.
Characteristics: High processing precision and high production efficiency. However, it is slower when processing complex shapes, difficult to process hard materials, and has low material utilization.
Specialized Machining
Definition: Also known as electrical discharge machining (EDM), it is a processing method that directly uses electrical energy, chemical energy, acoustic energy, light energy, etc., to remove excess material from the workpiece to achieve a specific shape, size, and surface roughness.
Specific Methods: Includes electrical discharge machining (EDM), wire cutting, electrolytic machining, electrochemical polishing, electroforming, chemical etching, ultrasonic machining, laser processing, etc.
Characteristics: Independent of the workpiece's hardness, it can achieve the effect of using soft materials to overcome hard materials and can process parts of various complex shapes. It has been increasingly widely used in mold manufacturing.
Plastic forming
Definition: Primarily refers to cold extrusion molding, where a hardened forming die is forcefully pressed into an unhardened die blank, imprinting the shape of the forming die onto the pressed die blank to create the desired mold.
Features: No surface finishing required, fast molding speed, can produce molds with various complex shapes.
Casting
Definition: For molds with low precision and lifespan requirements, casting is a simple and convenient method for rapid forming.
Features: Fast molding speed, easy to produce molds with complex shapes. However, the mold material is relatively soft and has poor heat resistance, resulting in a short mold life. It is mostly used for trial production and small-batch production.
Welding
Definition: Welding pre-machined modules together to form the desired mold.
Features: Simple processing, unlimited size, but precision is difficult to guarantee, prone to residual thermal strain and internal stress. Primarily used for manufacturing large molds with low precision requirements.
CNC Machining
Definition: Using CNC machine tools and CNC technology to process mold parts. CNC machining programs are created based on the part drawings and process requirements, input into the CNC system, and then the relative movement of the cutting tool and workpiece in the CNC machine tool is controlled to complete the machining of the part.
Features: High machining accuracy, high production efficiency, and capable of machining mold parts of various complex shapes.
Sheet Metal Machining
Definition: The process of machining the overall structure of a mold using various methods such as cutting, compressing, and grinding metal sheets.
Features: Capable of machining complex molds with thin metal sheets, and also capable of machining fine cavities with thick metal sheets.
Milling
Definition: A process of performing various milling operations on mold parts and the mold as a whole, including edge milling, end milling, external milling, deep hole milling, and large-diameter hole milling.
Features: Often used for mold parts with multiple holes and complex mold assembly structures.
Fine Machining
Definition: A process of achieving cost savings and improved mold precision through fine machining techniques.
Specific Methods: Commonly used methods include diamond fine machining, high-speed cutting, low-speed cutting, and double-sided grinding.
Other modern machining technologies:
Five-axis high-speed milling: Enables the machining of complex three-dimensional surface parts, significantly improving machining efficiency and surface quality.
Wire EDM: Primarily used for machining two-dimensional and three-dimensional ruled surface parts, achieving very high precision and surface roughness.
Electrical Discharge Machining (EDM): Ideal for handling complex shapes, narrow slits, and deep cavities in molds, achieving high-precision and high-quality machining results.
