145423-AUG 2013.pdf

August 2013

Volume 16 / Number 8

DesigN / bu ilD / repAir

Raising the Bar on Better

Moldmaking PG 30.

FEATURES

Finding the Right High-Feed

Indexable Milling Tool PG 37.

Inspecting Highly Complex

EDM Projects with Industrial

CT Scanning PG 43.

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PublisherClaude J. Mas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

Metalworking Group PublisherTravis J Egan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

Editorial DirectorChristina M. Fuges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

Senior WriterSherry L. Baranek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

Economics EditorBill Wood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

Contributing Writer, Special Projects Jan Bottiglieri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

Art DirectorCarla M. Turner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

Advertising Production ManagerBecky Helton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

MoldMaking Technology magazine (ISSN #1098-3198) is published monthly by Gardner Business Media, Inc., 6915 Valley Avenue, Cincinnati, Ohio 45244. 800-950-8020, 513-527-8800, Fax: 513-527-8801, gardnerweb.com. Canadian Agreement #40012278.Nonqualifed subscription rates per year are $89.00 in the United States, $99.00 in Canada and

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Media, Inc., 6915 Valley Avenue, Cincinnati, Ohio 45244.Entire contents copyright 2013. No portion of this publication may be reproduced in any form

without written permission from the publisher.Views expressed by the bylined contributors should not be construed as a reflection of the opinion

of this publication. Publication of product/service information should not be deemed as a recommen-dation by the publisher. Editorial contributions are accepted from the moldmaking industry. Contact the editor for details. Product/service information should be submitted in accordance with guidelines available from the editor.Change of address: Send old label as well as new address to Circulation, MoldMaking Technology

magazine, Gardner Business Media, Inc., 6915 Valley Avenue, Cincinnati, Ohio 45244.Periodicals postage at Cincinnati, Ohio and at additional mailing offices.

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2 MoldMaking Technology August 2013

6915 Valley Avenue Cincinnati OH 45244-3029P 513-527-8800Fax 513-527-8801 gardnerweb.com moldmakingtechnology.com

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Great Tips from This Issue5TRICKS OF THE TRADE

Contents


Features

30 Automation Raising the Bar on Better

Traditionally customized moldmaking to complete automation.

34 Mold MaterialsConsiderations for Mold Base Material Selection

Choosing the right material affects application profitability and cost.

37 Cutting ToolsFinding the Right High-Feed Indexable Milling Tool

The value of versatility and reliability in your high-feed machining solution.

40 Software Are You a Control Freak?

Using simulation to determine the right valve gate sequence.

43 Inspection/MeasurementInspecting Highly Complex EDM Projects with Industrial CT

Scanning

Industrial CT scanning plays an integral role in the EDM process.

46 Mold Maintenance/RepairIn the Trenches

Shaving with Occam's Razor, Part 2.

Departments

6 From the Editor: Mainstream Moldmaking?

6 Whats New on MMT Online: Business Strategies

8 New Business Opportunities: Plasticraft Molds, Inc.

10 Your Business: RTI and On-the-Floor Learning

12 MoldMaking Business Index

14 Profile: Crest Mold

18 Case Study: EDM

22 Case Study: EDM/Machining

27 Case Study: Machining

48 Product Focus

53 MoldMaking Marketplace

54 End Market Report: Aerospace/Defense and Energy/Power Generation

55 Ad Index

56 TIP: EDM

On THE COvER

Image courtesy of Rexam Mold Manufacturing (RMM; Buffalo Grove, IL; rexam.com/mold). This months cover shows RMMs Mega-Cella production system that ties together all available opportunities to automate and control the mold manufacturing process. See feature story and video link on page 30.

Images courtesy of (left to right) Buss Precision Mold, Kennametal and CAE Services.

1. Imagine That When you inject 400 plastic into a 350 mold material fows back into itself on the backside of seal-offs, reinforcement fbers cross link, thin ribs fll without diffculty and minimal wall thicknesses are easily achieved. PG. 14.

2. Roughing It Roughing strategies can be more effective with the correct high-feed milling application, since high feeds and shallow axial depth-of-cut make it possible to produce components to near net shape. PG. 37.

3. Freak Out Being a control freak in the injection molding world isnt such a bad thing when it comes to designing your molds. PG. 40.

4. Back and Forth Industrial CT scanning in EDM helps go from the problem steel back to the process quickly, and accuratelyimproving quality control and reduc-ing costly rework. PG. 43.

5. Keep an Eye on Tension An AWF system that includes a wire tension monitoring device enabling continuous observation is important. PG. 56.

August 2013 Volume 16 / Number 8

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From the Editor


Mainstream Moldmaking?Will moldmaking in the mainstream help attract a future

generation? Going to the source to get honest answers may help.

Christina M. Fuges

Editorial Director

It continues to amaze me how kids today still dont

find manufacturing exciting; or, is it that weve

just done a very poor job of marketing ourselves.

I strongly believe the latter is the hard truth, and

something which we need to address hard and fast!

I was recently part of a meeting that started off

just wanting to hear from moldmakers about their

needs, and how weand other like-minded orga-

nizationscould do a better job of serving them.

Well, that meeting quickly revealed what you prob-

ably already know: the only thing really on their minds is, What are we

going to do about our nonexistent future skilled workforce?

To me it boils down to the fact that manufacturing as a wholeand mold

manufacturing even more sosuffers from bad PR. Perhaps we arent seeing

any interest because we are not selling ourselves appropriately. I believe we

need to go mainstream to catch the attention of that next generation. So,

what do we do?

There are so many current efforts, and although many are wonderful,

none hit that mainstream mark. Maybe instead of talking amongst ourselves

to find the answers, we need to go right to the source12- to 16-year olds,

a critical age for this type of exposureand ask them what makes them

tick. What motivates them to buy, to engage, to participate, to want to learn

more? Then craft the appropriate marketing campaign to capture the solid

interest of some future mold manufacturers! Lets face it, they cant know if

they like something, if they dont know it existsor what it can do for them

academically, socially, financially, etc.

Below is a very small sampling of some videos. Run them by some 12- to

16- year olds you know, and see what they think.

http://www.youtube.com/watch?v=oQLVT0bfgaU&feature=youtu.be

http://www.youtube.com/watch?v=fTYPrx3RRaI

https://edgefactor.com/edgefactorshow

http://www.youtube.com/watch?feature=player_

embedded&v=IehkopSMnRY

This issue in particular does have some exciting content. Take our

lead story for instanceRaising the Bar on Better (page 30). It takes a

look at moving away from traditionally customized moldmaking toward

a level of complete automation (be sure to check out the video). It really

shows the endless possibilities to thinking outside of the box and effecting

worthwhile change. Oh, and this issue also includes our quarterly Additive

Manufacturing Supplement3D printinga subject that has gone main-

stream and picked up the interest of our kids. Something to think about.

Follow MMT on: Follow @MMTMag

MMT Zone: Leadtime Leader Awardsmoldmakingtechnology.com/zones/business-strategiesTodays mold manufacturer needs to be as much a business-man as a craftsman, so it is crucial to pay attention to the management issues facing your shop includingsales & mar-keting plan, global initiatives/strategies, banking and finance, workforce development and new business opportunities.

Browse Business strategies Zone by Type: Article | Columns | Case Study | Videos | Blog

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New Business Opportunities

Wiping the Slate Clean with a Brand-New Facility

By Sherry L. Baranek

In its 22-year history, Plasticraft

Molds, Inc. (Richfield, WI) was

sold to another moldmaker in

2003 and subsequently shut

down before President Eric

Marlow reopened it in 2006. So,

when an overcrowded building

made workflow difficult, Marlow

jumped at the chance to break

ground on a new facility, wipe

the slate clean and have a facil-

ity to form to our business, not

our business to form to a facility.

Plasticraft builds plastic injec-

tion molds for the automotive,

medical, industrial automation

and consumer products mar-

kets. According to Marlow, the

company was operating at more

than full capacity at its previous location. We knew we had to

move into a larger facility, and didnt feel it was advantageous

for us to lease a larger facility, he recalls. We also looked

at purchasing existing facilities. Existing facilities have good

value in this economy, but we werent able to find anything

that fit our business.

Therefore, the company built a facility from the ground

upand left room for expansion, which Marlow anticipates

happening within the next five

years. Marlow worked with a

local commercial builder who

had experience with custom

facilities. He notes the pro-

cess took approximately 14

monthssix months of design

time and eight months of build

time. The new building stands

at 11,000 square feet, more

than double the size the previ-

ous facility occupied at 5,000 square feet.

Marlow has taken full advantage of the extra space, adding

a Milltronics VM25XP 50 taper machine for roughing core

and cavity components and machining mold bases. We saw

the need in that department as we were forced to outsource

this machining last year, he notes, and we had to wait to

purchase it until the move. The new facility boasts a confer-

ence room, three private offices, six semi-private work sta-

tions, and a fully equipped lunch room/kitchen with an out-

door patio. The company also added an Engel 150-ton press

to increase its sampling capacity for larger tools (it already

has an 80-ton press).

The move was both physically and mentally demanding

on the entire Plasticraft team, Marlow notes. After the two-

week transition period, we were operating smoother than we

were at our previous facility, he states. We had some inter-

nal changes that included a change in management (now

we have a core group that manages the work flow), more

employee responsibilities and better scheduling abilities,

which make us far more organized. Everyone stepped up to

the plate and organized their department so the work flows

smoothly to the next department.

Marlow would like that success to continue, and is antici-

pating another expansion within five years. We put our best

work into our tools, and that shows all the way through into

the style and layout of our new upscale facility, he con-

cludes. We have had steady growth since re-starting in 2006.

Our sales have grown 25 to 30 percent annually since then;

and we doubled our sales in 2012. We have to keep a close eye

on costs making sure we can get the most out of everything

while maintaining high quality mold building.

For more iNFormatioN:

Plasticraft Molds, Inc. / (262) 251-6800

[email protected] / plasticraftmolds.com

After the two-week

transition period, we

were operating smoother

than we were at our

previous facility.

Plasticraft Molds, Inc. recently broke ground on a new facilityrather than

fnd an existing facilityto ft its growing business.

Phot

o co

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sy o

f Pl

asti

craf

t M

olds

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Your Business


By Ryan Pohl

Apprenticeship training is the foundation of any viable skilled

trade. The methods involved in the practice have evolved

through the years, but with respect to the last 75 to 100 years,

apprenticeship has always included some type of classroom

instruction (often called Related Technical Instruction or RTI)

combined with structured on-the-floor learning.

This approach shows respect to the diverse amount of

hands-on experience and the depth of knowledge necessary to

be successful in this industry. There are many different occu-

pations in this industry that can use the apprenticeship system,

but their requirements varya common breakdown of RTI

to Shop Hours is 576 Related Instruction hours to 8,000 Shop

Floor hours. In this article, we will explore some of the essen-

tial elements that are often incorporated into both portions of

a modern apprenticeship program.

First, it should be understood that the RTI and shop floor

experience should follow a somewhat parallel path. For exam-

ple, the early portion of an apprenticeship program should

include the most basic shop floor tasks and the most basic

RTI classes. Depending on whether or not the apprentice has

previous experience from a tech-

nical training school, this often

means covering basic machining

principles during the class time

while at the same time having

the apprentice do something at

the skill level of machine set-ups,

block-squaring or hole-making.

We have to be careful to

not push the apprentice into

advanced machining respon-

sibilities before they are ready.

Though the apprentice may not

admit it, s/he may begin to feel overwhelmed and unprepared

for his/her job. This may impact overall performance and per-

haps even prompt them to quit the program or even their job.

When designing an apprenticeship program, the employer

has a great deal of flexibility. Regarding the RTI, my number

one recommendation is to ensure the classes that the appren-

tice takes are absolutely relevant to their job and career. Today

that means incorporating elements of modern manufactur-

ing in the RTIsuch as classes on everything from Lean

Manufacturing, Problem Solving and Advanced CNC Concepts

to Leadership and Communication. The RTI can be delivered in

many modern ways as well. The employer could decide to have

their local technical school provide the instruction or they could

choose to teach the classes themselves internally. Of course there

are excellent online resources available that more and more com-

panies are incorporating. We will get into more details about the

Related Instruction piece of the program in a future article.

As for the shop floor component of the apprenticeship pro-

gram, again there is tremendous flexibility. This portion of the

program is all about providing the apprentice with hands-on

experience that you, as the employer, will consider important

both in the short-term and in the long-term. The apprentice

should have some exposure to nearly all jobs on the shop floor.

This can include everything from benching/polishing, mold

building and CNC operations to CAD/CAM and welding. Even

if all the apprentice will do primarily is run a CNC machine, it

is still critically important that s/he has exposure to the other

responsibilities on the floor.

In upcoming articles, we will continue to break down the vari-

ous elements of apprenticeship training. In the meantime, it may

be helpful for you to sit with your management team and discuss

how your company is training your employees. Start to make a

list of the necessary job knowledge and skills for each position.

This will help you determine how apprenticeship training can

be used to sustain your workforce in the future.

contRiButoR

Ryan Pohl is President of Expert Tech.

For more inFormation:

Expert tech / (616) 785-5733

[email protected] / expert-technical.com

Regarding the RTI,

my number one recom-

mendation is to ensure

the classes that the

apprentice takes are

absolutely relevant to

their job and career.Ph

oto

cour

tesy

of

Tech

Mol

d an

d C

reat

ive

Tech

nolo

gy.

Finding, training & Retaining EmployeesRTI and On-the-Floor Learning

Part 4 oF a series

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Vertical Edition

MoldMaking Business Index


month, and the rate of expansion is

holding steady.

The prices received in the moldmak-

ing sector actually strengthened in June.

The Prices Received sub-index for the

month was 51.7. The upward momen-

tum in the sub-index for Materials Prices

continued abated somewhat in the

second quarter, as the Materials Prices

sub-index came in at 63.7. So materi-

als prices continue to rise, but the rate

of the gains are moderating. Supplier

Delivery Times continue to get just a tad

longer, as this component posted a 52.5

in June. Offshore orders extended their

downward trend to 12 months. The

Exports sub-index was 44.0.

Total MoldMaking Business Index for June 2013: 50.1

Our latest survey of the North American moldmaking indus-

try indicates that overall activity levels held steady in June

when compared with the previous month. The MoldMaking

Business Index for June 2013 is 50.1.The latest index value is

a 0.2-point decrease from the May value of 50.3, and it is a 5.4-

point decrease from the 55.5 value posted in June 2012.

Though our total Index slipped when compared with the

previous month, some of the underlying indicators suggest

that conditions were actually just a bit better. And the fact

that the overall index has held steady throughout the entire

first half of this year is quite encouraging. We are right now

at the point in time when the negative effects of the federal

budget sequester and the increase in the payroll taxes will

have the maximum impact on the economy.

In the second half of this year, the effects of these events

will start to decrease. So the fact that the moldmaking

industry is holding steady in the face of significant head-

winds in the prevailing economic conditions suggests that

this industry will expand rapidly once the overall economy

starts to gain some upward momentum.

The New Orders component registered a surprisingly

good 53.3 in the latest month, which means that the level of

new business was moderately better when compared with

the previous month. The Production sub-index of 52.9 indi-

cates that work levels also increased when compared with

the previous month. The respondents to our survey con-

tinue to report that backlogs are getting shorter, but they

are doing so at a slower pace. The Backlogs sub-index crept

up to 43.8 in June. The Employment component was 53.8,

which means that payrolls were higher for the sixth straight

Our MoldMaking Business Index stayed very close to the 50-line through the frst

half of 2012. The growth rate in the overall U.S. GDP data during this period was an

anemic 1%. It will take a faster rate of economic growth than 1-2% to generate an

increase in spending for capital equipment, which will in turn create demand for

new molds and tooling. The good news is that despite the sluggish growth in the

overall economy, demand for new molds has held steady. This suggests that the

mold industry is poised for robust growth once the overall economy can generate

some sustained upward momentum. This will most likely happen next year. The

residential construction sector has fnally entered a full-fedged recovery, and

the nations employment fgures are starting to improve steadily. Both of these

trends will push household incomes higher, and after a few months this will result

in increased consumer spending. We expect economic growth to register a gain of

2% in 2012, and it will accelerate to greater than 3% in 2013.

Sub-Indices June May Change Direction Rate Trend

New Orders 53.3 53.1 0.2 Growing Faster 6

Production 52.9 52.8 0.1 Growing Faster 6

Backlog 43.8 41.9 1.9 Contracting Slower 14

Employment 53.8 53.8 0.0 Growing Same 6

Exports 44.0 47.2 -3.2 Contracting Faster 12

Supplier Deliveries 52.5 53.2 -0.7 Lengthening Less 18

Material Prices 63.7 61.6 1.9 Increasing More 18

Prices Received 51.7 49.7 2.0 Increasing Decrease 1

Future Business Expectations 65.4 67.4 -2.0 Improving Less 18

MoldMaking Business Index 50.1 50.3 -0.2 Growing Less 2

55

50

45

40

60

1/13

12/12

11/12

10/12

9/12

8/12

7/12

6/12

5/12

4/12

3/12

2/12

1/12

12/11

2/13

MoldMaking Business Index

3/13

4/135/136/13

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Crest Mold Technology: On the Cutting Edge of R&D

Canadian mold manufacturer Crest Mold Technology

(Windsor, ON) was established in 1987 by Willie Cipkar

still owner and presidentto build high-precision, non-

automotive molds prior to entering the automotive tooling

sector in the mid 90s. Being located in Windsor, it was logi-

cal to pursue a mold business for the auto industry, which he

believed had one of the most voracious appetites for tooling

due to the continuous styling changes of plastic components.

According to Ed Bernard, Crest Molds Manager of Research

and Development, the company has always focused on inno-

vation and advancements that give customers a competi-

tive edge. With over 30,000 square feet of manufacturing

space and 60 highly skilled and motivated employees, Crest

continues to invest in R&D on behalf of our customers best

interests, Bernard comments. Crests designers focus on

adequately robust molds capable of producing certified accu-

rate parts at optimized cycle times; and Crests moldmakers

concentrate on continuous improvement for efficiencies in

processing the various steels and alloys on the latest Makino

and Toshiba machining centers.

Tops in Technology

Developing and applying technologies to benefit customers

makes Crest a creative and dynamic workplace, Bernard notes.

Crest has an alliance with Matsui of Japan and Cinpres of the

United Kingdom for rapid heat cycle molding using cyclic pro-

cess thermodynamics via project-specific mediums.

The companys designers recently spent time in Japan and

have been working with Matsui since 2006 to establish a

technology transfer method that would include the intellec-

tual property costs so that they are invisible to the customer,

according to Bernard. Including Cinpres in the alliance made

perfect sense from the perspective of additional marketing

expertise, an entire distribution network, and an opportunity

to combine technologies like gas press, gas assist, microcel-

lular foaming and water injection, along with rapid heat cycle

molding apparatus solutions, he comments.

Bernard explains that approximately 10 years ago a technolo-

gy was developed in Japan to satisfy rigid environment rules for

recycling painted plastic parts. The rapid heat cycle molding

methods were created to heat a mold cavity to near glass transi-

tion temperature for high gloss appearance (replicating the look

of piano black painted parts on flat screen TVs and monitors)

with rapid cooling (for curing quickly enough to eject the parts

from the mold) being achieved within a competitive production

speed cycle (taking into consideration the absence of painting

cost and environmental impact expenses), he elaborates.

Crest Mold recognized that the same conceptswhich

were developed for high gloss appearancecould be adapted

to improve structural integrity of almost any plastic parts by

producing mold conditions, which would allow plastic mate-

rials to flow longer distances at lower pressure. This would

result in a uniform dispersion of polymer chains and the rein-

forcing fibers intended to improve physical performance and

reduce cost for its customers, Bernard notes.

Crest has been developing design concepts for molds capable

of temperature changes, within a competitive production cycle,

where the mold cavity surface changes from near glass transi-

tion Tg down to cured ejection levels using cyclic process ther-

modynamics. Because petroleum-based plastics have a broader

thermal range for processing than renewable biomaterial plas-

tics, adaptation and acceptance of biomaterials into the market

has not yet occurred, Bernard states. But, initial experiments

with cyclic process thermodynamics and the application of

rapid heat cycle molding technologies have produced samples

of injection molded complex automotive part geometries using

100 percent biomaterial-based polymers, as well as petroleum-

based plastics with as high as 40 percent biomaterial fiber rein-

forcement, in competitive production cycle times.

Uniting with Universities

The company is also currently engaged in ventures with three

major universities for projects including Biocomposites and

Biomaterials Processing and is also initiating research support

with the Microcellular Plastics Manufacturing Laboratory for

automotive light-weighting applications using RHCM surface

enhancement technology.

Once again, the company formed an alliancethis time

with a university for R&D efforts. Personnel from The

Crest Mold innovations make molders more productive.

Phot

o co

urte

sy o

f C

rest

Mol

d Te

chno

logy

.

Profle



Crest Mold Technology

(519) 737-1546

[email protected]

crestmold.com

University of Toronto have been working hand in hand with

Crest design staff at the Crest facility. After demonstrating

our technological capabilities to Ford Motor Company, the

improved thermal control aspects were identified as poten-

tially being able to overcome flow issues with an experimen-

tal bio-material that was being developed in cooperation

with the University of Toronto and introductions quickly led

to collaboration.

Continuous stability, even during the recent global down-

turn, is the result of a systematic approach to problem-

solving and a clear focus on innovation, Bernard adds. Crest

designers have also recently discovered that accepted indus-

try processing limitations can be overcome with enhanced

cyclic process thermodynamic control systems, which are

capable of radically changing the boundaries of previous

molding cycle limitations.

Plastic used for injection molding requires high heat to

flow and low heat to cureso pretty much every mold in

production ends up running at a compromised temperature

somewhere between the correct high injection temperature for

filling and the proper low temperature for quick curing and

ejection, Bernard continues. Once the single compromised

temperature is established, its up to the injection pressure to

force the already curing plastic into the cavity details of the

mold, he says. Cresta pioneer of various types of two-short

moldsis now engaged in a systematic investigation of tech-

nology applications and combinations of processes, which

are anticipated to change the paradigm for plastic processing

parameters, especially with emerging applications for biomateri-

als and nanocomposites. Biomaterials typically have a smaller

thermal processing range than their petroleum-based counter-

parts and to make things even more challenging, biomaterials

are characteristically more viscous, so optimized thermal con-

trol in the mold is essential, he adds.

Every plastic parts manufacturer knows what happens when

one tries injecting 400-degree plastic into a 100-degree mold. It

doesnt get very far without numerous gates and lots of injec-

tion pressure. Bernard explains, You end up with non-uniform

densityresulting in warp and distortionas well as flow

marks and knit lines on the backsides of seal-offs. Imagine what

happens when you inject 400-degree plastic into a 350-degree

mold. Material flows back into itself on the backside of seal-offs,

and reinforcement fibers actually cross link, thin ribs fill with-

out difficulty and minimal wall thicknesses are easily achieved.

What you probably didnt imagine was

the phenomenon of a resin-rich surface,

which completely replicates the cavity

surfacewhether bright gloss or matte

textureand which completely buries

the reinforcement fibers.

Focus on the Future

Crest Mold Technology recognizes that

the companys success is dependent upon

making its customers successful. Intense

investigation of technologies that can be

advanced for applications that give our

customers an edge is what Crest Mold

research and development is all about,

Bernard concludes. Working with mold-

ers to produce stronger, lighter weight

parts, using less energy with lower mate-

rial costs, Crest is determined to be the

leader for optimized cycle time with

guaranteed reliable tooling.

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Case Study / EDM

By Jan Bottiglieri, Contributing Writer, Special Projects

Pushing technology to the edge is standard operating pro-

cedure for NyproMold in Gurnee, IL. Recently Pete Smith,

Group Leader EDM-WEDM-Graphite, explained how the

addition of a new EDM machinethe Mitsubishi MV1200-R

Advance Plushelped the shop reach new heights of effi-

ciency and performance. Im very impressed; its a fun

machine to run, Smith says. Processing speeds are so much

more advanced than even five years ago, and it has made a

big difference for us.

Founded in 1987, NyproMold builds plastic injection molds

for the healthcare, packaging, consumer, and electronics

markets. The company has two facilities: the 35,000-square

foot Gurnee facility boasts the same high-level capabilities as

the larger headquarters facility in Clinton, MA.

More than 50 percent of

the shops work serves the

medical industry, and that

tight-tolerance work is a dif-

ferentiator for the company.

Our facility manufactures

molds ranging from one cav-

ity, all the way up to 128 cavi-

ties or more. We pride our-

selves on being able to quickly

accommodate part changes

from our customerswe can

make a whole new stack of

components, and theyre com-

pletely compatible with the

existing mold frame. The only

way you can do that is if youre able to hold tight tolerances,

Smith explains.

Because Mitsubishis MV series EDM machines feature

the latest technology in auto-threading, internal machine

communication, power supply and operating cost reduction,

it seemed like a great fit with NyproMolds focus on giving

customers high performance. At the 2012 IMTS show, the

company purchased three of the MV1200-R Advance Plus

wire EDM machines: two for the Clinton location and one

for Gurnee.

The MV 1200 Rs non-contact cylindrical drive system

makes it possible to reach a new level of precision, Smith

reports. We can cut pockets and different tapers that a lot

of machines cant cut with conventional machining, he

says. The motors are literally running on magnets, without

the wear issues of running on ball screws, like traditional

machines. It is able to hold a much more precise positioning.

The machines automatic feed adjustment has been anoth-

er huge advantage, says Smith. Any time youre using a wire

EDM, theres a feedback factor. When the wire gets too close

to the material or starts to pull too far away as youre cutting,

your feedrate needs to adjust, he explains. The quicker you

can respond to thatand were talking millisecondsthe

more consistent your cut is going to be, and the faster youll

cut because youre cutting as efficiently as possible. This

machine has changed wire EDM in a way that the machines

Ive operated have not been able to do, because it cuts sub-

stantially faster than its predecessors, yet it consumes about

40 percent less wire.

Down to the Wire

That lower wire consumption, coupled with faster operation

and wire recycling, is a winning equation for Smith. The

Imag

e co

urte

sy o

f N

ypro

Mol

d.

MV1200-R Advance Plus wire EDM.

New EDM Pushes

Performance and

Precision

This machine has

changed wire EDM in a

way that the machines

Ive operated have not

been able to do, because

it cuts substantially faster

than its predecessors,

yet it consumes about

40 percent less wire.


Case Study / EDM

newer machines chop wire instead of just spooling it out like

angel hair, so you get a bit more money back when recycling,

he says. Its not a new technology, but it does make it easier

to handle. We pay about $6/lb. for wire, and our recycling

yields around between $2.85 and $3.15/lb., so were getting

almost half the money back; and by using less wire, the

profitability is going up substantially. I get 50 percent back

by recycling, plus about twice as much work done with the

same amount of wire, and getting it done faster. There are no

negatives there.

Plus, the threading mechanism is far superior to any

other Ive experienced, Smith adds. Anyone who has run a

wire for a long time knows that to get your unattended run-

ning time, the machine needs to thread independently while

youre home in bed. Lets say the part

has 100 holes, when you come in in the

morning, you dont want the machine

to have missed 60 out of 100. You want

it to have threaded every one.

Smith was able to witness the MV

1200 Rs advanced threading system

when he stopped by the shop over a

long weekend to put a new spool of

wire on the unattended machine. The

wire had broken in the middle of a cut.

Normally when that happens it can

be difficult to retrace that path, but

this machine actually rethreaded right

through the cut.

Smith cites the machines high capac-

ity as a deciding factor when selecting

the MV 1200 R. At the time, NyproMold

had taken on some jobs projecting a

very high volume of wire time, and the

new machines helped the company

deliver on time, with great results.

Final Advice

Smith says that just 10 years ago he

There has been a kind of Aha!

moment in the application of tech-

nology. Machine manufacturers

began to look at not only how

were generating the spark, but

also how were responding to the

spark. We were not responding

quickly enough. The result has

been the better threading capability,

the increased processing speed.

I will never doubt again how far

technology can go.

moldmakingtechnology.com 21

suspected that EDM technology had gone about as far as it

could. We would joke that its just a 10-thousandth wire,

theres only so much electricity you can put into it. But I

didnt realize how much the computing side of it had been

holding EDM back, he says. I think theres been a kind of

Aha! moment in the application of technology. Machine

manufacturers began to look at not only how were generat-

ing the spark, but also how were responding to the spark. We

were not responding quickly enough. The result has been the

better threading capability, the increased processing speed. I

will never doubt again how far technology can go.

He offers this example. Ive got an EDM machine that we

bought in 2010. We did some time trials and, at the time,

that machine cut about 30 percent faster than our previous

machine, which wed purchased in 2006. That is a pretty big

jump in just four years. Our new Mitsubishi wire EDM cuts

about 30 percent faster than that. The technology basically

obsoleted our 2010 machine. And thats just a two-year peri-

od for the same increase.

Smith says that service is a key factor when buying a new

EDM. Because of the economy, some manufacturers seem

to have made major cuts in their service area. In my opinion,


MC Machinery Systems, Inc. / Mitsubishi EDM

630-616-5920 / mitsubishi-world.com

NyproMold / (978) 365-4547

nypromold.com / [email protected]

service is huge. If your machine goes down youre not just

not making money, youre losing money. Mitsubishi does a

great job. They have an outstanding training program.

Finally, Smith recommends that moldmakers shopping

for an EDM look for bang for the buckthat perfect bal-

ance of profitability and accuracy. He concludes, There

are machines out there that might be able to cut with even

higher precision, but they cost three times as much. It really

depends on your shops needs.

Renishaws laser melting system is a pioneering process capable

of producing fully dense metal parts direct from 3D CAD.

From tooling inserts featuring conformal cooling, to lightweight

structures for aerospace and high technology applications,

laser melting gives designers more freedom, resulting in

structures and shapes that would otherwise be constrained by

conventional processes or the tooling requirements of volume

production. It is also complementary to conventional machining

technologies, and directly contributes to reduced lead

times, tooling costs and material waste.

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Case Study / EDM / Machining

GW Plastics (Bethel, VT)a global leader in plastic injection

molding and contract manufacturing offering in-house mold

design and buildwas looking to become more competi-

tive when working on multi-cavity molds and also wanted to

decreased sinker EDM and bench polishing operations. This

set off their search for the right technology solution.

A Rich History of Growth

With its world headquarters located in the picturesque Green

Mountains of Vermont, GW Plastics has built a reputation as

one of the industrys most respected precision injection mold-

ing and contract manufacturing companies. GWs focus is

on injection molding, tooling and contract manufacturing of

precision thermoplastic and silicone assemblies (and compo-

nents) for the healthcare, automotive, consumer and industrial

marketsall these markets being safety critical. GW excels at

close-tolerance mold building, injection molding and contract

assembly with a matrix of competencies geared toward innova-

tive problem solving, Six Sigma quality, speed-to-market and

global manufacturing.

GW Plastics was founded more than a half-century ago

when two early plastics pioneers, John R. Galvin and Odin A.

Westgaard, decided to combine their extensive business and

materials engineering experienceand their initialsto start a

plastics injection molding firm. After building GW into one of

North Americas premier precision injection molders, they sold

the company to Carborundum in 1973. After a series of large-

company M&A transactions in the 1980s, GW ultimately found

itself owned by Standard Oil of Ohio (Sohio). In 1983, a group

of the companys managers and investors led by Frederic Riehl

purchased GW Plastics from Sohio. GW has remained closely-

held, under the same ownership to this day. In 1998, Brenan

Riehl became President and CEO after a successful career with

Owens-Illinois and General Electric assuring a successful lead-

ership transition and continuity of ownership.

The 1990s ushered in a period of rapid growth for GW, driv-

ing significant expansion of the companys manufacturing

capabilities and its geographic reach across the U.S. In 1990,

GW relocated and expanded its moldmaking facility to a new

Technical Campus in Royalton, VT. In 1992, GW expanded

into the Southwest opening a new facility in San Antonio,

TX; followed by a new plant in Tucson, AZ in 1996. GW fur-

ther expanded its Royalton Technical Campus by opening a

Technology Center dedicated to statistical mold qualification

and new technology development in 1997, and by establishing

its Royalton, Vermont Medical Molding facility in 1999.

In 2007, GW expanded globallysimultaneously into

two hemispheresby adding facilities in both Mexico and

China. In 2008, GW announced its entrance into the Liquid

Silicone market with GW Silicones in Royalton, VT. In 2012, in

response to increased demand, GW completed an expansion of

its GW Silicones operation at its Royalton, VT location.

With eight facilities operating from six locations worldwide,

equipped with six class 8 cleanroom molding and assembly

areas, GW has grown to a combined 350,000 square feet of

environmentally-controlled injection molding, tooling and

contract manufacturing space supplying market leading OEMs

across the globe.

GW invests heavily in both salaried and hourly workforce

training with a focus on quality to ensure its associates are

trained in the latest technology and manufacturing tech-

niques. GW accomplishes this through an in-house apprentice

program and classroom training in partnership with local tech-

nical colleges to ensure an adequate supply of skilled personnel

to support its growing needs.

GW is, consequently, seen as a preferred local and industry

employer with a motivated workforce and exceptionally low

turnover. Among senior management, the average term of

employment is 20 years, salaried employees have an average

tenure of 13 years, and hourly employees average eight years

(a remarkable hourly seniority for a 24 x 7 manufacturer). GW

currently has a large number of hourly and salaried employees

with service between 20 and 50 years.

Imag

es c

ou

rtes

y o

f S

od

ick

and

GW

Pla

stic

s.

Mike Ryon, EDM Specialist at GW Plastics with the Sodick AG60L sinker EDM,

which has an X, Y, Z travel of 23.62 x 16.54 x 14.57 (600 x 420 x 370 mm) and

can accommodate workpieces up to 3,307 lbs (1,500 kg). This sinker EDM is also

linear motor driven and comes with a 10-year positioning accuracy guarantee.

Traditional Labor

Values Meet

Linear Technology

The moment you realize that new requirements do not

require new equipment.

This is the moment we work for.

Contact and optical scanning technology allows the new O-INSPECT 322 to do the work of a CMM,

a microscope, a profile projector, and a contour measuring instrument. One machine for all of your

inspection needs.

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// multifunctionality made By Zeiss



Technology Investment Proves Successful

GW realized in 2007 that they needed to improve their time

frame from which they could bring a product to the market

from the initial concept/design stage. They knew that speed to

market was critical. They needed to purchase new, high tech-

nology machines to do so. GW was also looking to cultivate/

train its labor force along the way.

GW evaluated its machining options, and decided that Sodick

machines were the way to go to meet their goals. GW Plastics is

committed to continuously investing in precision tooling tech-

nology, states Timothy Holmes, GW Plastics VP of Engineering.

Over the past few years we have purchased a Sodick wire

EDM, sinker EDM and high-speed mill, he goes on to say. In

2010 GW first purchased the linear motor driven AG600L wire

EDM and a few months later added the

linear motor driven AG60L sinker EDM.

They then added the linear motor driven

HS650L high-speed mill in 2011. In 2012

GW decided to add an additional AG60L

sinker EDM and integrate a System 3R

Robot between the two sinkers.

The AG600L has an X, Y, Z travel of

23.62 x 15.75 x 13.78 (600 x 400 x 350

mm) and can accommodate a workpiece

up to 2,204 lbs (1,000 kg). This wire EDM

features linear technology and has a

10-year positioning accuracy guarantee.

The AG60L has an X, Y, Z travel of 23.62

x 16.54 x 14.57 (600 x 420 x 370 mm)

and can accommodate workpieces up to

3,307 lbs (1,500 kg). This sinker EDM is

also linear motor driven and comes with

a 10-year positioning accuracy guarantee.

The HS650L is Sodicks high-speed

mill that has linear motor drives and a

40,000 rpm spindle. The X, Y, Z travel is

24.41 x 19.69 x 11.81 (620 x 500 x 300

mm) and has a rapid feedrate of 1,417

ipm (36 m/min).

What GW gained was high reliability,

improved speed/throughput without

sacrificing accuracy or quality and a high

level of satisfaction from the operators,

Jim Comette, CNC Specialist at GW Plastics with

the Sodick HS650L high-speed mill, which has linear

motor drives and a 40,000 rpm spindle. The X, Y, Z

travel is 24.41 x 19.69 x 11.81 (620 x 500 x 300

mm) and has a rapid feedrate of 1,417 ipm (36 m/min).

Mold OPEN

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on all the machines. GWs technicians enjoy the friendly control,

reliable threading and decreased maintenance.

This Sodick equipment has increased our throughput and

machining accuracy, which is crucial to meeting speed-to-mar-

ket requirements for the tight tolerance precision thermoplas-

tic and silicone injection molds that we manufacture. The new

equipment in our Royalton, VT Mold Division, in conjunction

with our adjacent Technology Center where we immediately

begin the GW Plastics scientific molding process development

phase, provides us with a significant competitive advantage for

new program launches, stated Holmes.

GW was very impressed with Sodick Product Manager, Tom

Hipp. While at IMTS a GW staff member saw the demonstra-

tion on the HS650L and was impressed with the surface finish

that was achieved. He requested Hipp to

come in for a follow up visit, after the

IMTS 2012 show in Chicago.

With a strong engineering back-

ground, Hipp was able to optimize

their program to even further improve

their surface finish during his visit to

GW. GW wanted to achieve a 10.6

micro inches Ra surface finish on the

HS650L, states Hipp. I went in and

improved the process to achieve the

requested surface finish and within a

few hours they were up and running

with their desired surface finish. They

just needed a few tweaks with the CAD/

CAM program they were running to

reach the full potential of the HS650L,

Hipp adds.

GW has now become more competi-

tive working on multi-cavity molds due

to their two Sodick sinker EDMs and

System 3R Robot; while the purchase of

the Sodick HS650L high-speed mill has

greatly decreased their sinker EDM and

bench polishing operations.

They were also happy with the

seamless installation, training and

implementation that Sodick offered.

Sodick Engineers were on hand to get

the machines installed right away, and

offered training so GW was up and

running in no time. GW states that the

cultural fit between the two compa-

nies made the process of installation

and implementation much easier than

expected.

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Case Study / Machining



Manpower, Machine Time Maximized with

Highly Accurate VMC


By Sherry L. Baranek

Buss Precision Mold Inc. (BPM; Clackamas, OR) may be small

in number with 10 employees, but possesses the technology

namely a DMC 105V Linear VMC from DMG/Mori Seiki USA,

Inc. (Hoffman Estates, IL)of a larger shop to tackle molds up

to 36 x 48. This includes collapsible core, unscrewing, over-

molding tools and complex action designs needing extremely

high accuracy across the entire machining envelope. It was

for these reasons the company sought a machine with a larger

work envelope without sacrificing accuracy.

According to BPM President Jonathan Buss, tolerances and

finishes on the companys molds are tailored to the specific

project, but most work is held to +/-.0002 tolerance on multi-

cavity components, cavity, cores and parting lines. Thus, BPM

needed a larger capacity machine that would provide the

tolerances required as well as allow through-spindle coolant

for drilling operationsfor deep holes, which are required for

ejector pins, cap screws, waterlines and other mold compo-

nents through thick plates and also allows spindle orientation

for tapping routines. Plus, if the

machine had through-spindle

coolant capabilities, BPM would

not have to change machines to

drill different holes.

Thus, when BPM began a

search at IMTS for a high-

speed milling machine with a

larger size capacity, through-

spindle coolant capabilities

were a requirement. I gathered

information from prospective

builders, reviewed their offer-

ings and then picked several to

see in person at IMTS, Buss

recalls. We had high-speed machining centers, but we could

not drill or tap holes on them. We wanted a machine with the

additional solution of through-spindle coolant and tapping

on a 18K spindle.

Conquering Challenges

Buss decided upon the 105V for its larger machining enve-

lope (due to the portal or bridge construction), linear drives,

glass scales and through-spindle coolant capability with an

18K-RPM spindle for drillingas well as millingon the

same machine. Most high-speed milling machines do not

offer through-spindle coolant for drilling ejector pin holes,

or thread milling so they must be moved to another machine

for that process, he notes. We can eliminate a step in the

manufacturing process for pre-hard steel molds. Buss adds

the machine work envelope access is superior to most vertical

machines of any configuration, allowing unrestricted access

to two sides of the machine table.

DMG/Mori Seiki USA Executive VP Randy Harland points

out that this machine does extremely well in mold shops

for the reasons Buss outlines above. The construction of the

machine, its rigid bridge-type design, and the control tech-

nology give the 105V a unique advantage in milling of mold

cores and cavities, he says.

The machine also yielded improved surface finish. The

linear motors produced a noticeable surface finish advantage

of the ball screw machines, Buss elaborates. We have run the

same exact program, cutting tools, steel material and machin-

A 12-foot long compression mold for continuous molding of a rubber

conveyor belt.

Using highly accurate

machines allows more

effcient utilization of

manpower and machine

timesaving time and

money for the customer

and making BPM more

proftable.

Video

Access video

at end of article.

Pho

tos

cour

tesy

of

Bus

s P

reci

sio

n M

old

Inc

.



ing parameters on the ball screw machines, and the results are

very impressive. The improved surface finish requires less pol-

ishing when specifications such as texturing or mirror finishes

are required.

Furthermore, the DMG linear drives are extremely accu-

rate, without any axis reversal errors, Buss continues. In

recent ball bar runs, the technician thought his testing unit

was malfunctioning as he had never seen a machine test so

accurately on a round test pattern, he explains. He had to

make the program out of round to confirm it was actually

following the prescribed path, and once he saw the change in

test data, reverted back to the original programconfirming

his initial testing. He stated numerous times he had never

seen a machine so accurate.

Expanded Work, Uninterrupted

Buss is satisfied with the way the 105V has allowed BPM to

take on the building of larger molds, or allow multiple work-

pieces to be setup and run without interruption. One of our

first jobs that utilized the extra machine travel and accuracy

on the DMG was a 12-foot long mold for molding continu-

ous conveyor belt sidewalls, Buss recalls. It was made up Shop Manager Joe King fnish milling on the DMG DMC 105V Linear.



DMG/Mori Seiki USA, Inc. / (847) 593-5400 / moriseikius.com

Buss Precision Mold Inc. / (503) 652-5804

[email protected] / bussprecisionmold.com

Haimer-USA / haimer-usa.com

Lyndex-Nikken Inc. / lyndexnikken.com

OSG Tap & Die Inc. / osgtool.com

Video: mold roughing http://short.moldmakingtechnology.com/bussrough

of four 3-foot sections. We would not have previously taken

on a project of this size without the added travel of the

machine.

Additionally, Buss points out that these machines have

allowed his moldmakers to concentrate on getting their

jobs done, instead of chasing around machining tolerance

or thermal growth errors. And, the company has reduced

leadtimes significantly over when it was using conventional

machinery. Buss says it is hard to measure the leadtime

reduction definitively as workpieces vary. However, he says in

some cases the company has spent less time polishing com-

pleted molding surfacesat times up to 50 percent.

Keith Foster, Account Manager at DMG/Mori Seiki dealer

Ellison Technologies (Grand Rapids, MI), adds, Our DMG/

Mori Seiki customers that utilize DMG high-speed linear

technology have seen great improvements in mold contour-

ing accuracy and surface finish qualityall with a reduced

cycle time. Another benefit often overlooked is that they get

longer cutting tool life, which helps reduce cutting tool costs

for their jobs.

Using high accuracy milling toolslike OSG cutters and

Haimer or Lyndex/Nikken toolholders on the DMGallows us

to take advantage of the accuracies and speed of the machine

for a complete process, Buss concludes. Using highly accu-

rate machines allows more efficient utilization of manpower

and machine timesaving time and money for the customer

and making BPM more profitable.

Automation


By Jan Bottiglieri, Contributing Writer, Special Projects

Raising the Bar on Better

Moldmakers love the idea of better. Most continually

ask the same two questions: (1) How can we build

this better, more quickly, more efficiently, with less

cost and effort? and (2) How can we build a better one?

For Len Graham, Business Unit Leader at Rexam Mold

Manufacturing (RMM) in Buffalo Grove, IL, the question of

better doesnt stop with the single part produced or with the

steps taken to produce it. After 46 years in the moldmaking

industry, he is working to create a new way of approaching

the entire process: its called the Mega Cell.

Graham and his team are collaborating with companies

including System 3R, Mitsubishi EDM, Solidworks, Delcam

and GF AgieCharmilles, along with RMMs dedicated team, to

turn his revolutionary idea of better into a functioning reality.

At the heart of the project is a desire to move away from

a traditionally customized approach to moldmaking, and

toward a level of complete automation that raises the bar

on accuracy, repeatability and control. A manufacturing

A look at one project to move away from traditionally customized

moldmaking toward a level of complete automation that raises

the bar on accuracy, repeatability and control.

unit cannot effectively process the same thing being done

multiple waysalthough this is the norm for moldmaking as

we all learned it, Graham explains. Each craftsman would

create an end product by working on it in his own preferred

way, but an automated system will freeze, or at least drasti-

cally lose efficiency, if it is fed work in that way.

In contrast, the Mega-Cell is a production system that ties

together all available opportunities to automate and control

the process. In doing this, enormous dividends are being

paid not only within the more automated areas, particularly

the Mega-Cell, but in all areas operating. Far fewer mistakes

are made, and with strict first article inspection, any errors

are found immediately and thus corrected at very low cost

on whole.

Imag

es c

ourt

esy

of R

MM

.

The Mega-Cell is a production system that ties together all available

opportunities to automate and control the process.

Video

Access video

at end of article.


Beyond Super

The Mega-Cell has its roots in a project Graham began about

a decade ago, working as Director of Tooling/Engineering

with Tech Groups C/EC Division in Scottsdale, AZ, on what

was then called the Super-Cell. While that project generated

a lot of industry interest, it never quite reached completion

before the company was sold; the technology available at the

time had not caught up with the idea.

The same companies that originally supported that project

are on board for the Mega-Cell. We have a lot more bullets

for our gun this time, Graham says. The idea can be viewed

as a process patenta way to do something unique. This

version is a variation of that process, but updated to the tech-

nology available today.

When complete in about five to six years, the Mega-Cell

will be the worlds first fully automated mold manufacturing

system. It will consist of two automated manufacturing

systems: a rail system on one side of the shop for manufac-

turing mold inserts, and machining centers and a larger-

capacity rail system on the other side for manufacturing

mold plates.

The mold insert manufacturing rail system will have

five rails, each approximately 30 feet long; each will have

one robot feeding five or six pieces of equipment. Each rail

will have a CMM to verify and track all critical-to-function

dimensions on pallet-mounted mold components and elec-

trodes, and all machining disciplines needed to manufacture

these components will be represented on the lineplans

include high-speed machining centers, jig grinders, surface

grinders, laser engravers, and more, all robot-ready.

Component carousels will pass components from one rail

to another and back again as required to keep all machines

operating efficiently. Rotary carousels and bookshelves are

in place to carry small, medium and larger sized mold com-

ponents. The robot can automatically change arms/hands to

facilitate changing different style pallets to carry the compo-

nents. Pallet sizes range from 2 1/8 sq. in. (the smallest) to 12

sq. in. (the largest).

Smaller pallets go into the machines on a robot switch-arm

that can take one pallet in and remove one from the machine

in one trip. Each pallet includes an embedded radio-frequen-

cy (RF) chip; a technician scans the chip, identifies the piece

on the pallet, and assigns the machining programs/work

being done to it for processing and inspecting. The center of

all design, programming, manufacturing, and inspection is

a pallet-mounted high-precision gage ball. Each component

has a single point of reference that is consistent with all

machines and inspection associated with it on the line.

After the mold insert/electrode manufacturing unit is

complete on one side of the shop, it goes to the other side,

where there will be horizontal machining centers and a larger

capacity rail system for manufacturing the mold plates for

the mold bases. This system will use the same auto-locating

feature as the mold insert manufacturing unit, with the pal-

letized gage ball.

The idea in both scenarios is to be able to place a work-

piece into a machine robotically and begin machining and

inspecting without the need to use probing or some other

ancillary means of finding it before machining/inspecting can

begin, Graham explains.

We simply use the solid models of the components associ-

ated to the component receivers/holders. All mold plates will

join the mold components on the same end of the shop for

assembly on the benches. Assembly benches are just outside

the mold sampling room, so that everything moves in one

direction until becoming a completed, sampled and shipped

mold tool.

Customers and Collaborators

The Mega-Cell is monitored with cameras and machine con-

trols provide Internet access; this allows customers to see

LeArn MoreVisit our Automation and Machining Zones for more information

on a variety of machining technologies including milling, grinding,

boring, drilling, as well as automation solutions.

Go to moldmakingtechnology.com/zones for a complete list.

When complete in about fve to six years, the Mega-Cell will be the worlds

frst fully automated mold manufacturing system. Here is a System 3R robot

working in the cell.

Automation


and monitor the work being done on their mold components,

and to view inspection reports for every detail as long as

their work remains in the machines. Customers have always

wanted three main things from their moldmakers: molds

built with the lowest practical cost, delivered sooner and of

the highest qualitymost consistent across all dimensions

for all cavities achievable, Graham says. The Mega-Cell can

run 24/7; it runs much of the time untended, without labor

cost; and consistency is the operative word, as it will do the

same thing, the same way, throughout an entire series of

parts, without varying the process. Of course the cost savings

is the last to be realized due to the high cost of development

and the time needed to fully realize the benefit, both in time

and dollars, of the investment.

Fortunately, when Graham arrived at Rexam almost 18

months ago, he found a team ready and willing to make

that investment. I told them that if we were going to do

this, I would need them to work very hard to fill in the


Rexam Mold Manufacturing / (978) 906-1127

rexam.com/mold / [email protected]

Video: mega-Cell: moldmaking automation http://short.moldmakingtechnology.com/megacell

RMM Business Unit Leader Len Graham observes Mega-Cell Technician Kris

Sampson as he scans RF (radio frequency) chips affxed to pallets for identifying

work being processed into the Mega-Cell automated production system.

wide technology and systemic gaps, since this would be

the first of its kind. This team has far exceeded my wildest

expectations.

The most difficult aspect of the transformation from an

old-style mold shop into a fully automated mold manufactur-

ing unit is developing the complete standardization that is

necessary for success. During the year prior to installing Rail

#1, each area of discipline (moldmakers, EDM specialists,

CNC machinists and programmers, mold designers, grinding

specialists and tooling engineers) held weekly continuous

improvement meetings to establish one preferred way of

performing every single task. Teams set standards for every

operation strategy for every area, as well as for every opera-

tion or duty.

Standards/procedures manuals are being developed for

every department; no one can work in the area without

reading and understanding the content of the manual, says

Graham.

The RMM team is not the only group on board with the

Mega-Cells potential. Something this exciting draws the

major players like flies, Graham reports. Everyone wants

to be associated with this project as it is poised to move

American mold manufacturing into and even beyond the

world-recognized, high quality arena that is widely known

to exist in Europe. Mega-Cell partners represent all the tech-

nologically advanced manufacturing countries in the world.

We will be happy to be able to say, Hey, we have an advanced

system that gives us the ability to engineer and build a pretty

darn great mold here in the U.S. too.

The customers have set the bar and it is up to us to clear

it, he concludes. I am not talking about RMM alone, but

mold manufacturing on the whole. In the not-so-distant

future, if a mold shop of stature does not make the transition

away from custom moldmaking to systematic mold manufac-

turing, there cant be much room for growthand that shops

survival will come into question, if they try to compete at

this high a level.

Mold Materials


By Paul Britton

Material used for mold bases is pretty straightforward.

The materials are common and have been around for

a long time; however, choosing the right material will

help save time and money. Generally, mold base material can

be broken down into three categories: hot rolled steel, chrome-

moly materials and stainless steel.

Hot rolled steel materials vary from low carbon steel

(A-36 or 1020) up to medium carbon steel (1045 or 1050).

These steels are easy to machine and have reasonable tensile

strength. They are easy to find and are very cost-friendly.

They are usually chosen when the customer has very low

production runs associated with the project.

Chrome-moly materials range from 4130, P20, 4140,

etc., have a hardness range from 28-34 HRC and have good

mechanical properties. They are ideal for cavity and core plates

as well as other plates required in the mold base. They can be

machined fairly well; how-

ever, in some cases with heavy

machining or grinding, a

need to stress relieve the

material may be required.

Stainless steel (a modified

420 F material that is used

for holder block applications)

is pre-hardened to 30-35

HRC. It offers good corrosion

resistance and has very good

machinability. The material is very stable and does not require

stress relieving. In applications where humidity is a problem or

corrosive material is being used this material works well.

Today there are two additional mold base materials to con-

sider. The first material falls in the stainless steel category

(see Chart 1). It is an improved 420 F material currently compet-

ing with 1.2085 in Europe. It has excellent machining qualities

and does not need to be stress relieved. By lowering the carbon

and chrome content, this material has improved machinability,

and has 10 to 15 percent better thermal conductivity than the

420 F material currently being used (see Charts 2, 3).

Choosing the right material can greatly affect

the profitability and cost of your application. Photo courtesy of International Mold Steel, Inc.

Two more mold base

145423-AUG 2013.pdf

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