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Great Tips from This Issue 5 TRICKS OF THE TRADE Contents 4 MoldMaking Technology April 2015 Features 24 Hot Runners Smart Tooling Combining cavity sensors with hot runner valve gate control yields new applications and greater process gains. 30 Mold Components In Search of the Infnite Processing Window Side-action preload can yield zero core movement during injection and help molders achieve a robust molding process. 36 Inspection/Measurement Control the Process to Drive Proftability Process control technology boosts productivity and profitability through increased throughput of good parts, reduced inspection time and dependable production schedules. 40 Cutting Tools Tooling Up for Challenging Cuts To maximize quality and repeatability, you need the right cutting tools, especially in challenging applications. Here's a guide for selecting tools for high-speed tool paths, tight areas, straight walls and graphite cutting. 46 Automation Adding Value with Robotics A robot may not directly make the final part, but it can add value to the overall process, if its use is properly planned and executed. ON THE COVER Ingersoll's Hi-QuadF high-feed face mill more than doubled through- put in a non-high-feed roughing application at Reko Manufacturing of Lake Shore, Ontario. The mill runs at 600 sfm and 300 ipm, with an extreme 0.050-inch depth of cut in P2 mold stock. The company says tool life doubled to 10 hours in the cut, and the spindle load dropped by half to 30 percent. The cutter combines high-feed and deep-cut geometry in an extra-thick insert in extra-rigid seating. The proprietary IN 4030 coating reduces friction and heat to protect the insert and spindle. See the related story on page 16. 1. Taking Control Individual, closed-loop pressure control at each gate can be used for extremely complex parts, family tools with drastic part-weight differences, higher cavitation of preci- sion parts and modular tooling. PG. 24. 2. Load it Up While any method of preload should provide an infnite processing window, the amount must be suffciently greater than any injection force, it must be maintained during injection, and core stops must be sized to accom- modate the force. PG. 30. 3. Feedback Wanted In-process control monitors and documents operations using probes to deliver intelligent feedback to the process and address variables such as temperature and tool wear. No operator intervention is needed. PG. 36. 4. Tool Up Toroidal tools are best for cutting tight areas such as helical bores and ribs, or when the cutter diameter is close to the radius of the part. The tool's robust, toroidal shape creates a chip-thinning effect that allows it to cut at faster feed rates. PG. 40. 5. CAD/CAM Science A value-added application of robotics is in making re- verse molds. The science isn't in the manipulator robot itself, but rather in the CAD/CAM system that helps the engineer create the reverse mold for the robot to machine. PG. 46. April 2015 Volume 18 / Number 4 36 30 24 VIDEO ACCESS Departments 6 From the Editor: The Power of People 6 W hat's New on MMT Online 8 EAB Insight : The Specialized Approach 10 Your Business: Protecting the Multi-Family Business 12 Profile: Advanced Mold & Tooling 16 C ase Study: Cutting Tools 20 Pellet 2 Part: Controlling the Heat Source 52 Pr oduct Focus: Cutting Tools 60 B y The Numbers: MoldMaking Business Index 62 End Mark et Report: Aerospace and Medical 63 A d Index 64 TIP: Hot Runners Cover image courtesy of Ingersoll Cutting Tools. Images above courtesy of (left to right) Synventive Molding Solutions, PFA Inc. and Renishaw.