How to shorten the manufacturing cycle of the mold with five axes?

Machining path planning

Complex surface one-time processing: The five-axis repeater can control the tool movement on five coordinate axes (three linear axes and two rotating axes) at the same time, which makes it adopt a more optimized tool path when machining the complex surface of the mold. For example, for injection molds with complex free-form surfaces, traditional three-axis machines may require multiple clamping and tool changes, and can only be processed from a specific direction. The five-axis repeater can realize one-time continuous machining of complex surfaces by adjusting the attitude and motion path of the tool, and reduce the conversion time between processing processes.

Intelligent path planning to avoid tool interference: In the case of complex internal structure of the mold, there are many deep holes, reverse buckle and other characteristics, the five-axis reloader can carry out tool path planning through the numerical control system, and automatically avoid the possible interference between the tool and the mold. This means that there is no need to manually adjust the tool path or change the tool frequently during machining, thus saving a lot of time. At the same time, intelligent path planning can also be based on the shape of the mold and processing requirements, select reasonable cutting parameters, such as cutting speed, feed, etc., to improve processing efficiency.

The ability to multitask and process simultaneously

Simultaneous roughing and finishing: The five-axis repeater can use the flexibility of its multiple axes to achieve simultaneous roughing and finishing at different stages of die processing. For example, when machining a large die-casting mold, it can use a larger tool to rough in a part of the area, removing a large amount of material, while in the area where the rough has been completed, using a smaller tool for finishing. This parallel processing method greatly reduces the overall processing time of the mold, because the traditional processing method requires the roughing of all areas to be completed first, and then the finishing.

Integration of a variety of processing: In addition to milling processing, the five-axis repeater can also integrate drilling, boring, tapping and other processing. In mold manufacturing, this means that a variety of different types of processing tasks on the mold can be completed on the same equipment, without transferring the mold back and forth between different machine tools. For example, in the manufacture of stamping dies, the five-axis repeater can first complete the milling of the mold cavity, and then the drilling of the cooling hole and the tapping of the screw hole, reducing the turnaround time and the number of clamping times between the mold and the different processing equipment.

Fast tool change system and degree of automation

High-speed automatic tool change device: The five-axis returner is usually equipped with a high-speed automatic tool change device, which can complete the tool change in a short time. The tool change time can be reduced to a few seconds or less, which is important for mold processing that requires frequent tool changes. For example, when machining molds with many different shape and dimensional characteristics, it may be necessary to use multiple tools for machining, and the rapid tool change system can ensure the continuity of the machining process and reduce the downtime caused by the tool change.

Automatic loading and unloading and processing process control: Through the integration with the automatic loading and unloading system, the five-axis repeater can realize the automatic loading of the die blank and the automatic unloading after processing. At the same time, its numerical control system can control the entire machining process, including automatic adjustment of machining parameters and optimization of machining sequence. This highly automated processing mode reduces the time of manual intervention, improves the processing efficiency, and further shortens the manufacturing cycle of the mold. For example, in the mass production of molds, the automatic loading and unloading system can be closely coordinated with the five-axis repeater to achieve 24-hour uninterrupted processing.