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Machining 24 MoldMaking Technology August 2015 A BETTER WAY Now you can get to root cause solutions with science-based technologies that are revolutionizing injection molding. - MeltFlipper® Rheological Control - Mold Filling Simulation - Therma-fo™ Material Characterization Learn more at Beaumontinc.com or call us today at 814 899-6390 ext 130. THERE'S GOT TO BE So how can mold builders do more with less while maintain- ing productivity and precision? The answer is by using machine tools that seamlessly incorporate multiple milling technologies into a single, automated, high-precision, five-axis machining process. Although five-axis machining is nothing new, and many shops have added this machining strategy to their list of capa- bilities, problems still persists in terms of productivity and pre- cision when using a multi-platform milling machine or on an "all-around" machining center that incorporates automation. To understand how to achieve this required productivity and precision with five-axis machining, it is important to first understand the difference between a multipurpose and a multi- platform machine. Multipurpose machining centers focus on simple operations, such as basic drilling, tapping and milling, while the advanced technology of multi-platform machines allows them to perform more complicat- ed tasks, such as hard-milling, high-speed machining and micro-milling. When looking at new machine technology, con- sider whether the machine spindle can be designed to handle low-speed hard- milling operations while being precise enough to drill a hole in a part as thin as a hair or fast enough to plow through aluminum at 1,200 inches per minute, and if it can handle a harsh graphite environment. A multi-platform machin- ing center is fully capable of being mul- tipurpose and can handle many different machining technologies. Productivity and Precision Considerations To further increase productivity with- out sacrificing precision, consider the machine's tolerance budget and the true definition of five-axis precision before investing in five-axis machining. One of the challenges to doing more on a machining center is the machine's accuracy budget. This is the total achiev- able tolerance that the machine is capable of holding on the parts. It is cal- culated from the total tolerances of all machine system components, however, it does not include the process budget or tolerance loss due to machining meth- odology. Part complexity determines the machining methodology, which may require that a part be processed on many different machines rather than on just one machining center. Every time the part is removed and set up on another machine, tolerance is lost, so the goal should be to perform as many processes as possible on one machine. If more can be done on one machine, it's more likely that tighter tolerances can be held, increasing productivity.