Mold manufacturing and processing of carbide tools
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In the field of metal cutting, no area demands higher precision than mold manufacturing, where tools must achieve a specific service life to meet strict requirements. Carbide tools, specifically designed for such high-precision tasks, offer unique advantages that make them ideal for this application. One such manufacturer, Fumeier, specializes in producing a full range of molds for various industries, including plastic injection molding, extrusion, and rubber injection. With a fleet of 32 machines, they can create molds of all sizes—from prototypes to mass production, with capacities up to 50 tons.
Most of their clients are from the automotive industry, but they also serve companies in computing, communications, transportation, and entertainment. As demand for faster delivery and higher accuracy increases, machine tools, cutting tools, and operators must perform at even higher levels. To improve efficiency, manufacturers invest in advanced equipment and specialized tools.
Modern machining equipment must be versatile, efficient in roughing, and precise in finishing, with the capability for five-sided machining. Tool changes should be fully automated to maximize uptime. The Droop & Rein Gantry FOG-S M30 milling machine (6500mm × 3200mm × 1500mm stroke) is an excellent choice, meeting all these requirements.
These machines operate for 16 to 18 hours daily, often running two shifts with night shifts and weekends used for time-consuming finishing work. Since the machines run automatically, tool life and accuracy are critical. To ensure optimal performance, Fumeier collaborates closely with tool manufacturers like Sandvik Coromant, who bring expertise in tool selection based on the specific needs of each project.
When setting cutting parameters, it's essential to consider both the tool material and machine capabilities, aiming for the best possible tool life. Tools like Coroguide Plura help streamline this process, making it easier to select the right tool for the job. This not only improves efficiency but also ensures consistent quality.
Employee experience plays a key role in programming, as it allows for tailored strategies that match the machine’s capabilities. Fumeier uses Tebis und Work NC software, which enables users to translate real-world experience into effective milling strategies. This system also integrates positioning angles and drive strokes directly into the program, enhancing accuracy and productivity.
During the programming phase, tool life and component quality are crucial factors. The use of advanced milling strategies and modern tools is vital in mold and tool manufacturing. Close collaboration with tool suppliers is equally important to stay ahead in a competitive market.
Hummel, another company focused on deep-draw molds, actively seeks high-efficiency tools. For example, when machining a 1.2738 steel mold (quenching strength of 1400 N/mm²) for a Volkswagen rear bumper, the challenge was the small outer contour and long tool flange, leading to full tool wrap. To solve this, they used the Coromill Plura 1610 carbide end mill with a reinforced extended holder, which provided stability and minimized vibration, ensuring a good surface finish.
Before machining, the workpiece weighed 36 tons. After 96 hours of initial contouring, the remaining weight was just 17 tons. The part then underwent roughing and finishing on a new machine for approximately 240 hours. This case highlights how choosing the right tool—matching the strategy with the carbide tool—is essential for efficient mold production.
Ultimately, the competition among mold manufacturers comes down to efficiency and innovation. Continuous development of milling tools and new strategies allows companies to improve production efficiency and stay ahead in the market. Strong partnerships between tool manufacturers and users are key to success in this ever-evolving industry.