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Machining 22 MoldMaking Technology August 2015 Productivity Meets Precision By Gary Zurek T oday's manufacturing environment remains extremely active and highly competitive on a global scale. To compete, manufacturers must constantly hone their internal technology while seeking ways to increase precision and effi- ciency, and reduce delivery times and costs. All this, while pushing the limits of doing more with less in terms of shop space, organization, staff skill levels, and overall machine performance and productivity. The past decade has introduced some major new developments in manufacturing, particularly in machining, including high-speed machin- ing, hard milling, high-performance machining, micromachining, multiplatform machining and high-dynamic machining. Many of these machin- ing processes have incorporated technologies that enable more precision in electrode, mold and die manufacture. While flourishing mold shops continue to embrace these changes and new technologies, small- to medium-sized shops that don't are vulner- able to losing market share and closing their doors. Although many shops have implemented these advancements, doing more with less is not an easy task. This article will address the "doing more with less" strategy as it relates to five-axis machining. Technology Does Not Equal Productivity Most shops today employ some form of automa- tion, such as the production of electrodes or cores and cavities using EDM, or direct milling without human interaction. Automation has allowed man- ufacturers to do substantially more, but it hasn't necessarily increased productivity, because often a single part must be processed using multiple machining technologies, such as milling, turning, EDM and jig grinding. This can result in lost productivity and precision. With machine dynamics, mechanical design and thermal stability in control, mold manufacturers can take five-axis machining to the next level. Images courtesy of Kern. Five-axis positioning with an effective fxture design can bring productivity and precision to a new level. VIDEO Access video at end of article.