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Great Tips from This Issue 5 TRICKS OF THE TRADE Contents 4 MoldMaking Technology August 2015 Features 22 Machining: Productivity Meets Precision With machine dynamics, mechanical design and thermal stability in control, mold manufacturers can take five-axis machining to the next level. 28 Machining: Machining Complex Contours Advanced, integrated processor geometry eases processing and predicting of turn-mill contour operations and residual grinding stock allowance. 32 Cutting Tools Rethink Moldmaking with Digital Tool Knowledge Connecting digitized tool data with CAD/CAM, presetting, production and automated inventory control offers real-world productivity gains. 36 Mold Material The Potential of Enhanced Venting Materials Stop fighting venting problems with mold retrofits and prevent them by designing the original mold with an enhanced venting steel. 42 Shop Strategies Masters of the Details The right information, the right culture and a systems approach to every operation ensure nothing escapes the scrutiny of this team of mold manufacturing specialists. ON THE COVER Five-axis machining can bring exceptional productivity possibili- ties while achieving a high degree of precision, even in terms of five-axis positioning. Tightly designed machine kinematics are an important attribute, and when combined with an effective fixture design, multiple parts can be machined while holding high preci- sion tolerances on the parts. Tight kinematics also allow smooth, high-dynamic motion, which yields high-quality surface finishes. See related story on page 22. Cover image courtesy of Kern Precision Inc. Images above courtesy of (left to right) Versatile Mold and Design, Siemens Industry and International Mold Steel. 1. Tax Tips An IC-DISC can enable a mold builder to reduce overall income tax liabili- ties, but proper planning is necessary to ensure that it is established correctly and that tax benefts are maximized each year. PG. 10. 2. Wrestling with Wrist Type When reviewing robot wrist options, consider torque requirements, wrist weight and weight of payload (parts and runners), combined and the extra daylight needed for wrist, payload and movement. PG. 20. 3. Head in the Clouds Digital tool knowledge connected to automated vending on the cloud allows users to see the availability of an item pro- posed for a process plan, making both plans and budgets more effcient. PG. 32. 4. Info at Your Fingertips Machine operators can use workstation PCs to access schedules, job instruc- tions, revisions, CAD mod- els and real-time spindle utilization reports, which helps clarify priorities and avoid confusion. PG. 42. 5. Filter it Out Filter media (cellulose and synthetic) and bellows technology (single-bellow, double-bellow and triple- bellow) can have an impact on the effciency of the EDM process. PG. 64. August 2015 Volume 18 / Number 8 36 28 16 VIDEO ACCESS Departments 6 From the Editor: Manufacturing Matters 6 What's New on MMT Online: moldmakingtechnology.com 8 Editorial Advisory Board (EAB) Insight: Program Management 10 Your Business: Tax Incentives 12 Profile: Ameritech Die and Mold 16 Case Study: Inspection/Measurement 20 Pellet 2 Part: Assessing Robotics Requirements 50 Product Focus: Inspection/Measurement 60 By The Numbers: MoldMaking Business Index 62 End Market Report: Medical and Aerospace 63 MoldMaking Marketplace 63 Ad Index 64 TIP: EDM