Impulse to the productivity in the mechanised of moulds and matrices

The mechanised of moulds and matrices can arrive to be a costly business. With frequency, the material of the piece is expensive, and the programming and the mechanised are used to to be complex. Nevertheless, in a global market, can offer services of manufacture of tools to prices extremely competitive is essential for the survival of the business. With this in mind, Sandvik Coromant has a new strawberry that offers a productivity until 20% upper that the comparable tools of the competition; in fact, it offers a highly profitable solution to accelerate the processes of mechanised.

A lot of elements of the daily life produce in the sector of the moulds and the matrices. Between these articles find from blocks of cylinders and crankshafts, until bottles, carcasas of mobile telephones and soldiers of toy. The moulds of tooling, of forge, of injection and of finishing are only an example of the tools of complex form that reflect or copy with precision the form of the final piece that goes to produce in series.

In the production of moulds and matrices, the most important reduction of the cycles takes place in the operations of desbaste and semiacabado, since they are those in which it deletes the greater quantity of material. Nevertheless, the temperate steels used usually for the manufacture of tools (>45 HRc) are very difficult to mechanise, since they are used to to mill in his state toughened to avoid so the thermal sensors treatment affect to the geometry. Like consequence, in the last years, the manufacturers of tools of cutting have seen forced to find able technologies to accelerate this part of the process in materials like the P20, H13 and S7, among others.

The strategy of mechanised suitable is directly related with the election of the tools of correct cutting. Like result, the strawberry is a fundamental factor to guarantee the productivity and the profitability. The application of a high advance and an action of light cutting always succeeds in the milling cutters used to these effects. Here, the secret resides in a combination optimised of the design of the edge and the quality.

For this, Sandvik Coromant has developed a new strawberry that offers a productivity until 20% upper to the comparable tools of the competition. CoroMill 419 is a strawberry of plaquita interchangeable of big advance with five edges by plaquita, two more than the tools of the usual competition, that contribute a profitability added. This strawberry is specifically designed to provide an excellent performance in the operations of desbaste and semiacabado of temperate steels. The durable plaquitas of the strawberry, resistant and robust, offer a mechanised reliable to depths until 2 mm. When using plaquitas of parallel facet, the speeds of advance recommended (fz) for the applications of planned are between 0,5 – 1,1 mm/z. For the applications of milling of profiles, recommends the use of plaquitas radial.

The capacity of the strawberry to minimise the axial strengths derives directly of the application of an angle of position of 19° and an angle of positive axial inclination. An angle of position reduced generates a finer shaving, which, to his time, keeps a thickness of shaving adapted for the geometry of the plaquita. Likewise, a lower angle of position directs the strengths of cut in axial steering, to the husillo, which results in a greater stability and is less demanding with the machine. By this reason, when realizar operations of big advance, the milling cutters have to apply with a blur complete of the diameter, no inferior to the half of the width of his plaquita. The milling cutters with a blur inferior to the half of the width of his plaquita will see subjected to an effect of push and, since the cut will not be balanced, this probably will cause more vibrations.

Each plaquita CoroMill 419 has a total of five edges of cutting: the plaquitas are available in a wide range of qualities and five special geometries to the measure of the specific requirements. The geometry of the tool of cut plays a fundamental paper to the hour to control the thermal sensors effect, and influences in how forms and evacuates the shaving of the cut. A wrong geometry, often, can give place to a premature failure of the tool and create components with a finishing of bad quality; reason whereby the tools have to design specifically for the mechanised of temperate materials.

Regarding the temperature, the capacity of supply of refrigerante through the tool of all the milling cutters CoroMill 419 allows to apply refrigerante of air compressesed for an evacuation of shaving optimised in the milling of deep cavities and the helicoidal interpolation. This type of refrigeration is preferable because it avoids the thermal sensors fissures caused by the application of refrigerante by flood in the mechanised of temperate steels.

The mechanised of moulds is a complex discipline. Often it requires the planned of areas so much big as reduced, the mechanised of squares or deep walls and the mechanised of long slots, deep and narrow. Besides, the mechanised of cavities often requires operations of mechanised axial and in ramp. CoroMill 419 is indicated for operations of planned and milling of profiles, including the mechanised in ramp and the helicoidal interpolation, as well as the mechanised of greater scope, usual in a lot of applications of manufacture of deep and odd tools.

Along this range of operations, has showed that the planned of big advance puts fewer requirements in the tenacity and more requirements in the resistance to the heat and to the wear. These last can surpass, easily, applying a more resistant quality to the wear and/or to the heat. For example, for the planned of temperate steel, is recommended to begin with the quality GC1010 of Sandvik Coromant and, if it was necessary to contribute more hygiene, with the quality GC1030.

Thanks to his sustrato and coating multi-layer of PVD of TiAIN (nitride of titanium aluminium), the quality GC1030 offers to the users a resistance to the wear increased and a tenacity of the edge optimised. The quality resists well the routes of tool little favourable, the problems of stability, the long voladizos and the deep cavities. The big attribute of the TiAlN is his skill to work to temperatures until 800 ºC. This high thermal sensors resistance allows to the user apply greater speeds and advances without damaging the tool of cutting.

By the contrary, the milling of profiles of big advance in temperate steel demands a big tenacity of the plaquita. Thus, when producing squares or surfaces in 3D, or when mechanising in ramp or cajear, begin with a quality more tenaz can contribute big profits. Here, it is recommended to begin with GC1030 and optimise with GC1010.

The quality of plaquita of PVD GC1010 is indicated for any workshop that experience problems with the perpendicular fissures or the plastic deformation when mechanising in temperate steels. An excellent performance is guaranteeed. For example, when mechanising a component in temperate steel CMC 04.1 (50 HRc), GC1010 lasted 24 minutes. The depth of cut was of 2 mm, to a speed of 50 m/min and an advance by tooth of 0,11 mm.

Obviously, in the mechanised of moulds and matrices, the use of CoroMill 419 contributes multiple profits more. For example, the light action of cut, of big advance, generates less noise, what, to his time, gives place to some surroundings of work more favourable for the operario. The low consumption of power is another useful advantage, that few can ignore with the high prices of the current energetic market. Besides, the inherent design of the strawberry produces fewer wastes.

Designed to satisfy the philosophies of mechanised of the current operations of manufacture, CoroMill 419 is available in diameters until 100 mm to adjust to Coromant Attract, attachments of axis or cylindrical mangos.