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Issue link: https://mmt.epubxp.com/i/863778
moldmakingtechnology.com 59 SelfLube is the leading U.S. manufacturer of precision Mold and Die compo- nents ● Both conventional and self-lubricating ● Over 10,000 standard part numbers ● Customization available to accommodate special sizes and con- figurations ● We sell direct to save you time and money ● Call for a free catalog or visit us on-line SelfLube, Inc. Coopersville, MI USA ISO 9001:2008 800-690-3600 info@selflube.com Based on your experience, share some "lessons learned" about five-axis machining processes and technology, and describe any aspects that you feel could be improved for moldmaking. Don: First, select a machine tool company that has an expe- rienced staff of factory-trained technicians who really know how to service your machine tool and can provide fast, effi- cient service. Additionally, select a supplier that has a trained person on staff who understands the intricate, specialized software and post processors of the five-axis machine that you will purchase. Next, consider selecting a five-axis machine tool con- troller that will permit you to perform certain basic programming functions at the machine tool and will help make your off-line programmer available for other tasks. Then purchase a five-axis machining vise, which will enable you to machine much closer to the part and reach places that would otherwise be inaccessible with more conventional fixtures. You will not need to extend your cutting tools nearly as far from their tool holder as you usually do, which results in a more rigid machin- ing environment. Graphic Tool makes extensive use of magnetic tables to hold its workpieces and vises, and Graphic Tool frequently uses shrink-fit toolholders. (We use col- lets and conventional toolholders for roughing only.) Both strategies result in much closer tolerances. The shrink-fit technology helps to increase machine spindle life and decrease spindle runout. Finally, we highly recommend cross- training. The typical five-axis machine is an expensive piece of equipment, so it needs to be kept running. Cross training is an insurance policy that a purchaser of any highly complex, state-of-the-art equipment purchase should consider. Ed: We have several five-axis machines, but it took time to learn how to maxi- mize our use of them and figure out how to leverage the results we need. We investigated numerous cutter styles, speeds and feed rates depending on what material and function we were using. We try to optimize every situ- ation as it comes up so that we know exactly what we're going to get when the item is finished. At this point in time, we feel every piece that comes off our five-axis machines is spot on, and that level of optimization in our mold builds allows us to fit items faster and with less manual work. In turn, we achieve repeatability, which gives us consistency should the customer ever have a problem with any component in our tools and needs us to perform the work again.