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90 MoldMaking Technology July 2015 Pg. 5 Machining 90 MoldMaking Technology July 2015 FOR MORE INFORMATION: Okuma America Corp. / 704-588-7000 sbaldus@okuma.com / okuma.com Pages 73 to 90 Flexible, High-Speed Mold Machining By Scott Baldus Molds and dies come in all different shapes and sizes, and flex- ible high-speed machining plays an important role in their manufacture. Double-column machining centers are powerful, efficient machines with a wide range of functionalities. If you're in the market to purchase a double-column machine, there are several factors to consider before making an invest- ment. Ultimately, you need to decide upon the criteria that currently matters the most to you, while also considering what your manufacturing needs may be down the road. For example, which functionalities are the most important for large-mold machining? Multiple attachments, tolerance control, a compact footprint or bed size? Here are some variables that need to be considered when set- ting up particular specifications for a double-column machine: Vertical machining. Vertical machining is ideal for simple work like cutting holes in large plates. Simplicity is the name of the game, so a double-column vertical machine is ideal if you don't need five-sided functionality. With this type of system, the spindle is fixed and not easily changed out. Five-sided machining. Some double-columns can be config- ured with vertical and horizontal attachments that allow the machine to function as both a vertical and horizontal machine. If your part needs multiple-face machining, this functionality should be an important consideration. Rather than reposition- ing a part, the operator can machine it in one clamping, which produces a more streamlined approach to mold machining. Five-axis machining. This functionality allows for full five-axis part contouring. It is also useful for shape profiling and for light–to-medium cutting applications. In addition, five-axis allows for shorter setup times and reduced workholding require- ments, which generate more complete parts per operation. Five-axis indexing. For heavy-duty cutting applications, five- axis indexing functionality is essential. It's rugged and offers more powerful cutting options in one- to five-degree increments, and it is ideal for process-intensive machining such as moldmak- ing. This type of machining improves accuracy, reduces tool- change time and can yield significant increases in productivity. Tolerance control. Consider the type of tolerances your parts require, then look for a machine that offers options or enhance- ments on tolerance. High speed and accuracy are essential for increasing throughput, and with today's technology, you should not have to choose between the two. You can achieve high speeds without sacrificing quality, and a throughput advantage will give you a competitive edge in the marketplace. Enclosures. Double-columns are massive machines, so run- ning them in the safest manner possible should always be a pri- ority. Most people think enclosures are solely used to maintain operator safety, but they also keep the manufacturing area clean and neat. Jobs are contained, as coolant is prevented from spray- ing and chips from flying. Enclosures are mainly used for con- taining the bed however, rather than the entire machine. Bed size. The size of the parts to be machined will determine bed size. As mentioned earlier, be sure to consider your current and future needs, as beds cannot be changed out. Carefully pick a bed large enough to access all sides of the parts that you're cut- ting, especially if you will be manufacturing a part that requires multiple-face machining. Lastly, it may be a smart to consider a double-column machining center that is built specifically for your needs and desired functionalities. An off-the-shelf solution may not be the best fit. Weighing the benefits of the available functional- ities will help you decide which machine is best-suited for your moldmaking needs, both today and tomorrow. CONTRIBUTOR Scott Baldus is a product specialist at Okuma America Corp. Image courtesy of Okuma America Corp. This mold was machined with high speed and high accuracy on a double- column machining center with a universal index head (B/C axis) and a NC-BC universal head. VIDEO: Double Duty High speed and high accuracy in machining large molds and dies. short.moldmakingtechnology.com/doubleduty VIDEO Access video at end of article.