In the United States, Germany and Japan and other industrial countries, its tooling industry in recent years, a large scale technological revolution under way, which is gradually replaced with high speed cutting machine electric processing equipment, on the mold cavity for high precision machining. These tools include a variety of high speed CNC milling machines, machining centers.Currently in the mold manufacturing process, mainly ordinary electric spark machining and processing. General machining mold cavity are generally carried out before the heat treatment roughing, semi finishing and finishing, and then grinding, polishing, time consuming and laborious. EDM is a machining after annealing, followed by heat treatment, EDM, and finally polished, polished.

With the rate of consumer products to speed up replacement of mold productivity and manufacturing quality put forward higher requirements, EDM die low productivity and quality gradually exposed the shortcomings of instability. To shorten the manufacturing cycle and lower costs, have extensive use of advanced machining technology. The representative of advanced manufacturing technology, high speed cutting technologies, to meet the requirements of modern tooling and features.

High speed cutting technology for processing the main advantage of mold:

(1) greatly increased the processing efficiency, not only high speed machine tools, feed speed, and a rough finish can be completed, greatly improved production efficiency, combined with numerical control technology, mold manufacturing cycle can be shortened by about 40%.(2) high speed machining electrodes do not die, do not need to follow up grinding and polishing, but also easy to implement process automation, improved the speed of mold development.(3) The technology can process high speed cutting of hardened steel, but also of very high surface quality, surface roughness of less than Ra0.6, made by grinding and milling process on behalf of effects, not only saves a lot of time, also increased surface quality.

In order to achieve the relevant parts of the mold cavity and high speed processing, machine tool requires the following features:

(1) large load bearing and high rigidity is due to the large die is the direction of development, processing equipment must be large enough to travel with the work table size and adaptation. Now, a few tons to hundreds of tons of mold is very common to require a large machine can withstand the weight of the work surface. Mold material strength and hardness are high, and, often, greater elongation of the small diameter end milling mold cavity, the process prone to flutter. In order to ensure machining accuracy and surface quality, high speed machine tools for mold must have a high dynamic and static rigidity, to improve the positioning accuracy of machine tools, tracking precision and anti vibration capability.

(2) high speed and high power high speed machining is the development direction of high speed milling in the mold has showed great superiority. To meet the mold cavity surface processing, tool radius should be less than the minimum circle radius of the cavity surface, in order to avoid processing tool and the workpiece occurs “interference.” As the tool diameter and small, thus requiring very high spindle speed, spindle speed of high speed machine tools has reached 40000 ~ 100000r min, rapid feed rate up to 30000 ~ 60000min. Cavity and other parts mold parts thick, often finishing in one clamping of the workpiece and, therefore, spindle power to large, middle size of mold milling machine and machining center spindle power often 10 ~ 40kW, and some even higher.

(3) can be a good multi axis and the cutting ability of an integrated deep cavity mold cavity to complex multi space composed of 6 surfaces and grooves, and many have a deep cavity molds. In order to achieve high accuracy on the 3D surface, high speed and high stability of the processing, multi axis machine tool needs, and has good cutting ability of an integrated deep cavity. Can adopt five axis machining center, in addition to the three coordinates of linear movement, there are two rotating coordinates into a movement. Multi axis mill head or bench can feed a continuous rotation, which is suitable for machining complex surfaces of the mold cavity parts.

Complex processing is one of the development direction of mold. Though many processing centers have been able to complex machining processes to achieve a single machine, but still can not fully meet the mold, the mechanical processing and electrical, chemical, ultrasonic processing methods for various composite theory, both the technological characteristics of two or more complex process of mold manufacturing in the future will have broad prospects.

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