Machining open pockets
Mould inserts also have machining tasks that are required for casting or various attachment parts. Users are increasingly machining open pockets (circumferential machining) using trochoidal milling. This machining method helps to optimise machining times and to extend tool life.
Tool overview for the following machining steps:
Roughing
Roughing operations are responsible for most of the chip removal capacity. Special milling strategies such as high-feed machining or trochoidal milling can reduce machining time and thus increase profitability. In addition to tools with indexable inserts and solid carbide milling cutters, high-performance milling cutters with special roughing geometry are used.
Material residual desbaste
Após o desbaste, os usuários usinam o material residual, especialmente em cantos e cavidades, para uma tolerância o mais constante possível em uma segunda etapa de usinagem. Normalmente, são utilizadas ferramentas com raio da aresta ou fresa de alto avanço. Se necessário, uma fresa esférica também pode remover o material residual nos cantos.
Pre-finishing
If there are high demands on dimensional accuracy and surface finish, semi-finishing is recommended before finishing. With pre-finishing, machining approaches the final mould profile. The aim is to obtain a residual material that is as constant as possible in order to enable fast finishing with high demands on the surface quality. The stock removal after roughing is approx. 0.5-1 mm for hardened materials and 0.03-0.5 mm for soft materials. After pre-finishing, the constant stock removal is 0.05-0.1 mm for hardened materials or 0.1-0.3 mm for soft materials.
Schlichten
Die Schlichtbearbeitung trägt das verbleibende Aufmaß ab, um die finale Form zu erreichen. Nach der Vorschlichtbearbeitung beträgt dies 0,05-0,1 mm bei gehärteten Materialien beziehungsweise 0,1-0,3 mm bei weichen Materialien. Kugel- und/oder Eckradiusfräser sind das Mittel der Wahl, abhängig von den finalen Konturen des Werkstücks.
Finitura del materiale residuo
Le proprietà sempre più complesse degli stampi da produrre richiedono la fresatura del materiale residuo una volta conclusa la lavorazione di finitura, soprattutto negli angoli. A tale scopo, vengono di norma utilizzate frese a profilo sferico in metallo duro integrale.
