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moldmakingtechnology.com 13 ultra-efficient cutting. This led to the expansion of constant chip load cutting strategies, so that these tools can be used effectively. Now, a similar evolution is happening in the realm of finishing. New finishing toolpaths are in development to effectively drive new "shaped" cutting tools with cutting radii many times greater than conventional ball end mills. The toolpath's mission is to orient the tool to the part, allowing it to finish much larger areas per pass, while producing a better finish with fewer and shallower cusps. This emerging technology is not applicable to every mold surface. However, mold builders have realized up to 80 percent improvement in surface finish cycles on projects where they have used these new cutting tools. Faster Production In some shops, the starting point for generating a part pro- The ability to quickly and temporarily fill holes and remove features can help ensure smooth, high-precision finishes. Dynamic toolpaths deliver a consistent chip size and the most efficient use of tools, time and machines. aggressively as the CNC machine will allow with- out the user worrying about exceeding the tool's cutting capabilities, which can result in tool breakage or part or machine damage. Mold build- ers who have adopted this approach report a range of advantages that include mate- rial removal rate improve- ments of 25 to 70 percent or more, reduced tool wear, improved productivity and a reduction in overall cycle time. This machining strategy can also safely accelerate both the programming and CNC manufac- turing efficiency for the machining of electrodes. Mold builders who use contemporary tool- path strategies that maintain a consistent chip thickness report a substantial positive impact on lead- times and operating costs. This cutting strategy is one of the easiest things a mold shop can do to become more competitive. Better Finishing Strategies Machine tool builders, cut- ting tool vendors and CAD/ CAM software developers are continually challenging each other with new solu- tions that require each to constantly improve their own products. For example, some of the super-hard materials that are sometimes used in mold- making spurred cutting tool makers to develop advanced tool coatings, materials and geometries that would provide Great simulation will give you the confidence to use newer and more innovative machining strategies. Images courtesy of CNC Software, Inc.

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