MoldMaking Technology

JAN 2018

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Case Study / Machining 36 MoldMaking Technology —— JANUARY 2018 Model Die and Mold Inc. needed a CNC machine that could handle finish-machining of very large, contoured molds with deep, constricted areas like the one shown here. The Parpas Diamond Linear 30 gantry-style, five-axis machining center provided those capabilities and more, including faster cycle times and a significant reduction in EDM and other secondary steps like polishing. By Cynthia Kustush When building molds ranging in size from 150–5,000 tons, it is important to have CNC equipment that provides both the capacity and the capabilities to achieve accurate, efficient machining on a wide variety of jobs. It also helps to be able to confidently run jobs unattended and reduce, if not eliminate, the need for secondary processes. Model Die and Mold Inc. has 67 employees and builds molds fitting that size range for customers who are original equipment manufacturers primarily in the automotive, heavy truck, luxury vehicles and public transporta- tion industries. Monica Neibarger, proj- ect manager, says that the Wyoming, Michigan-based company manufactures between 150–300 molds a year, depend- ing on size. For a while, size was a challenging factor. "We were experiencing bottlenecks in our CNC finishing department, particularly with very large molds that had deep, contoured cavities. We had to outsource that work, causing a loss in profits," she says. In addition, Model Die had to turn new work away because of insufficient CNC capacity and required delivery times. To remedy the situation, the company began looking for a machine with a larger work envelope and, more impor- tantly, the ability to cut deep, contoured cavities. Model Die already had two Parpas Diamond machining centers from Parpas America Corp. in Bloomfield Hills, Michigan. One is an Active Five five-axis gantry high-speed CNC mill, and the other is a Diamond Linear featuring an over- head gantry and five-axis head. Each has XYZ travels of 87 inches by 59 inches by 39 inches, and Neibarger says that they have been top performers in terms of speed (20,000 rpm), surface finish, five-axis precision and automatic tool changing capability (84-position and 40-position, respec- tively). "Investing in a new, larger Parpas Diamond 30 Linear machining center made sense, given the excellent performance of the machines we had," she says, adding that the five-axis, gantry-style Diamond 30 provided the same benefits and more. Increased Capacity Wins Work Turning away work because of inadequate CNC capac- ity was frustrating for Model Die. Despite having another CNC Bridge Mill, which features a 44-inch Z travel, its table size maxed out at 72 inches by 136 inches. While the Images courtesy of Model Die and Mold Inc. MODEL DIE AND MOLD INC. PROBLEM: Recurring bottlenecks in CNC finishing made it necessary to outsource work, which reduced profitability. Additionally, the group needed a larger footprint to accommodate very large workpieces. SOLUTION: Parpas Diamond Linear 30 gantry-style, five-axis machining center. RESULTS: Increased speed and capacity. The machine provided the ability to finish-machine in tight areas, significantly reducing most secondary operations like EDM. CNC Gives Moldmaker More Capacity, Greater Reach for Large, Contoured Molds

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