196926-NOV 2013.pdf

NOVEMBER 2013

VOLUME 16 / NUMBER 11

DESIGN / BU ILD / REPAIR

Wire EDM

Goes 3D CAM for

Mold Operations PG 22.

FEATURES

Simulation Predicts

High-Conductivity

Insert Performance PG 26.

Maximize Results with

Copper Alloy Molds PG 30.

CASE STUDY

Better Molds in Less Time

with High-Technology

Machinery PG 18.

1113 MMT Cover.indd 1 10/15/2013 2:04:50 PM

selection, compatibility

and availability.

exactly how dating should be.

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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]

Managing Editor El McKenzie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]

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

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

Moldmaking Technology (ISSN 1098-3198) is published monthly and copyright 2013 by Gardner Business Media Inc. 6915 Valley Ave., Cincinnati, OH 45244-3029. Telephone: (513) 527-8800. Printed in U.S.A. Periodicals postage paid at Cincinnati, OH and additional mailing offces. All rights reserved.

POSTMASTER: Send address changes to Moldmaking Technology Magazine, 6915 Valley Ave., Cincinnati, OH 45244-3029. If undeliverable, send Form 3579.

CANADA POST: Canada Returns to be sent to IMEX Global Solutions, P.O. Box 25542, London, ON N6C 6B2. Publications Mail Agreement #40612608.

The information presented in this edition of Moldmaking Technology is believed to be accurate. In applying recommendations, however, you should exercise care and normal pre-cautions to prevent personal injury and damage to facilities or products. In no case can the authors or the publisher accept responsibility for personal injury or damages which may occur in working with methods and/or materials presented herein, nor can the publisher assume responsibility for the validity of claims or performance of items appearing in editorial pre-sentations or advertisements in this publication. Contact information is provided to enable interested parties to conduct further inquiry into specifc products or services.

2 MoldMaking Technology November 2013

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

Richard G. Kline, CBC | President

Melissa Kline Skavlem | COO

Richard G. Kline, Jr. | Group Publisher

Tom Beard | Senior V.P., Content

Steve Kline, Jr. | Director of Market Intelligence

Ernest C. Brubaker | Treasurer

William Caldwell | Advertising Manager

Ross Jacobs | Circulation Director

Jason Fisher | Director of Information Services

Kate Hand | Senior Managing Editor

Jeff Norgord | Creative Director

Rhonda Weaver | Creative Department Manager

Dave Necessary | Senior Marketing Manager

Allison Kline Miller | Director of Events

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Great Tips from This Issue5TRICKS OF THE TRADE

Contents


Features

22 EDM Wire EDM Goes 3D CAM for Moldmaking Operations: Wire EDM is now well-suited to tackle solid models, taper angles and surface finish.

26 Software Get the Red Out: Simulation predicts high-conductivity insert performance.

30 Mold MaterialsMaximize Results with Copper Alloy Molds: Common mistakes in the application of copper alloys in mold tooling.

34 Mold MaterialsLets Be Clear About Aluminum: Aluminum tooling can run almost any resin that steel can and produce millions of shots with unfilled resin with uniform results.

38 Mold MaterialsMaking the Right Mold Material Selection for Thermal Management

of Molds and Inserts: Productive thermal management of a mold.

42 Mold Maintenance/RepairIn the Trenches: I Need a Crash Cart in Here: What to stock in your shops crash cart.

ON THE COVER

Image courtesy of MC Machinery Systems Inc. / Mitsubishi EDM. The large taper part shown here demonstrates the high taper guides capability to maintain a more accurate angle and not cause scraping damage to the wire, making it possible to attain a 12-micro-inch Ra surface finish at a 45-degree taper. See story on page 22.

Images above courtesy of (left to right) StackTeck Ltd., Do-Rite Die & Engineering and

Phoenix Proto Technologies.

1. Getting it Right. With the right high-speed CNC, a shop can generally do all milling operations without moving a job to another machine. PG. 18.

2. Count on It. To evaluate ROI, look at the total cost of manufac-turing BeCu inserts versus the cycle time gainsin-cluding additional material and EDM time. PG. 26.

3. Theres Proof. It has been proven in many applications that using copper can result in molded parts being produced more quickly and with higher quality. PG. 30.

4. Misunderstood. The 7000 series of aluminum is good enough to use for an airplanes framework, but it is misunderstood to be too fragile to make a plastic component. PG. 34.

5. Taking Notes. A common tool used to drive improvement within a shop is called PDCAplan, do, check, adjust, which entails building the crash cart, implementing the plan and using a notepad. PG. 42.

November 2013 Volume 16 / Number 11

34188

VIDEO ACCESS

Departments

6 From the Editor: What is Affecting Your Value Chain?

6 Whats New on MMT Online: EDM

8 New Business Opportunities: Automation Cell

10 Your Business: Strategic Planning

12 MoldMaking Business Index

14 Profile: Workshop for Warriors

18 Case Study: Machining

46 Product Focus

53 MoldMaking Marketplace

54 End Market Report: Packaging and Aerospace

55 Ad Index

56 TIP: Automation

1113 MMT DEPT--Contents.indd 4 10/15/2013 2:05:43 PM

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THIS MONTH ON moldmakingtechnology.com

From the Editor


What Is Affecting Your

Value Chain?A new peer council has been formed to help answer that

question, and MMT was honored to be at the table.

Christina M. Fuges

Editorial Director

About a year ago, the Original Equipment Suppliers

Association established the OESA Tooling Forum

to provide a platform to discuss industry issues and

best practices in automotive vendor tooling that are

critical to the entire value chain. Now more than

ever, we need to address the most critical challenges,

and this Tooling Forum has begun to do just that.

I was invited to attend its September meeting in

Michiganstrictly to listen and learnand it was

very enlightening.

At the meeting, Carol Jean Milner and James Mastronardi, two purchas-

ing managers from Nissan, presented the automakers global tooling strategy.

The managers discussed Nissans approach to the tooling function in the U.S.

and Mexico for which they are responsible. They expressed interest in more

direct communication in the interest of forming collaborative and mutually

beneficial relationships with tool shops in the region to support the companys

global product expansion and growth.

A member roundtable discussion followed, which focused on exposing

current pain points. By far, the top two issues were getting paid and doing

business in Mexicoboth of which were tagged for further discussion dur-

ing future meetings. OESA and Harbour Results Inc. also shed some light

on a vendor tooling study they conducted to engage the entire supply chain

on best practices that eliminate waste within product development, purchas-

ing and manufacturing.

Overall, feedback on the effectiveness of the group is very positive. It

proves to be very informative and an excellent platform for many of the key

players in the value chain to express themselves and ultimately work toward

a more efficient automotive industry, said Mark S. Kunitz, director of pro-

gram engineering for Roush Global Tooling, who was attending his first

OESA Tooling Forum. Another first-time attendee, Dave Cecchin of Omega

Tool Corp., gave me his impression: It was a professional gathering of like

players in the industry with common goals and issues, without the distrac-

tion of suppliers, customers, lenders and other professional people. This

setting promotes more candid conversation across all tool, die and mold

makers.

However, the true value of this forum lies with having more tool, die and

mold makers commit to becoming members. Membership is open to inde-

pendent companies that manufacture molds, stamping dies and/or gages and

fixtures in North America. Members do not have to also be members of OESA.

Visit oesa.org/Councils-Committees/Tooling-Forum for more details.

Follow MMT on: Follow @MMTMag

MMT ZONE: EDMmoldmakingtechnology.com/zones/edmMoldmakers rely on electrical discharge machining (EDM) routinely. This refers to wire, sinker and small-hole EDM. Sinker includes an electrode and a workpiece both submerged in dielectric fluid; wire uses a thin wire to cut with electricity; and, with small-hole, an electrode is a cylinder used to machine a hole. Considerations for EDM efficiency include depth, accuracy and finish, and components to consider include drives, generator, programming system and flushing. Other facets include wires, electrodes, graphite, filters and fluids.

BROWSE PAST EDM ARTICLES BY TYPE: FEATURES, CASE STUDIES AND TIPS

Soft Wire Threading for Wire EDMing: Tips for Success Methods Machine Tools Inc. takes a look at EDM equipment that provides improved wire processing during the AWF cycle.

How EDM Training Can Boost Productivity POCO reviews how even the shortest of training sessions provides the opportunity to recover any costs incurred in a very short time.

EDM Efficiencies Excel A roundtable of technology suppliers discusses advance-ments in EDM processes in terms of machining speed and surface finish to improve overall accuracy, productivity and profitability.

SEARCH EDM PRODUCTS Milling/EDM/Laser/Automation Solutions, GF AgieCharmilles Die Sinker EDM/Machining Centers, Absolute Machine Tools High-Speed Electrode Machining Center, Sodick Wire EDM with Cylindrical Drive Motor, MC Machinery Systems/Mitsubishi EDM Graphite Products and EDM Accessories, Ohio Carbon Blank Inc.

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1113 MMT DEPT--Editorial.indd 6 10/15/2013 2:05:57 PM

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New Business Opportunities

Moldmaker Service Soars with Permanent Automation Cell on Site

By Sherry L. Baranek

StackTeck Ltd. is a manufacturer of high-volume production

tooling solutions for the packaging, medical and consumer

products markets located in Brampton, Ontario, that recently

invested in automation for its newest in-mold labeling (IML)

pilot cell. The company specializes in IML for a variety of

packaging applications for leading OEMs, and this investment

shows how it continues to vertically integrate to add more

capabilities to service its customers, particularly in automation.

Jordan Robertson, StackTecks general manager of busi-

ness development and marketing, says the demand for IML

prototyping has been ongoing and growing. To accommodate

this growing demand, the company purchased automation

systems from several equipment suppliers, including CBW

Automation out of Fort Collins, Colorado, which designs and

manufactures high-speed robots and downstream automa-

tion equipment for the plastics injection molding industry.

According to Robertson, this automation will maintain the

ongoing cell availability

to customers, unlike

with previous cells,

which used automation

equipment on loan from

automation suppliers.

CBW has been supply-

ing StackTeck with IML

automation systems

since 2007. We chose

CBW because they

have a very fast robot

system and offer North

American support, and they are very innovative and well-

suited to special challenges, Robertson says. We are very

familiar with their IML expertise, having done a wide variety

of applications with themincluding some big stack mold

IML projects up to 600 tons in size.

This system is capable of simulating the cycle time and

process of any IML production system. The end-of-arm tool-

ing for a prototype run can be sourced from any leading IML

automation supplier, which enables an accurate pilot version

of the production system for any high performance machine.

This time StackTeck is in a position to purchase the cell,

as opposed to borrowing it, Robertson says. Because we

have been working in the IML area for a while now, we are

well-known for providing this type of service, he says.

We are quite busy with the cell, which supports the cost to

purchase all of that automation as well as the decision to have

the dedicated cellincluding the machineonsite and avail-

able for customers.

The value of the IML pilot cell is that it minimizes the cost

of prototyping IML parts. A molder needs only to purchase

molding surface components, a mandrel and a magazine for a

particular IML project, Robertson says. The rest of the hard-

ware is already in place at StackTeck, including single-cavity

mold bases that are suitable for most packaging applications.

The current IML pilot cell is set up beside a 330-ton Husky

test machine, but this is a flexible setup that can be moved to

other machines when required. The system is equipped to run

a single-cavity mold with automated handling of pre-cut labels,

as well as for part de-molding and stacking automation.

According to StackTeck, this new automation helps facilitate

the introduction of new IML packages into the marketplace.

We will be very pleased when this is running all of the time,

Robertson says. There is a regular stream of projects coming

through, and we anticipate that to continue.

FOR MORE INFORMATION:

StackTeck / 416-749-0880

[email protected] / stackteck.com

CBW Automation Inc. / 970-229-9500 / cbwautomation.com

We are quite busy with the

cell, which supports the cost to

purchase all of that automation

as well as the decision to have

the dedicated cellincluding

the machineonsite and avail-

able for customers.

In-mold labeling (IML) cell.

Phot

o co

urte

sy o

f St

ackT

eck.

1113 MMT DEPT--New Business Opportunities.indd 8 10/15/2013 2:04:14 PM

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Your Business


By Bill Phillips

The business plan. What a concept. And when used correctly,

what a great tool to keep you, your people and your business

focused on the right things, and keep the company headed in

the right direction.

However, before the plan can be used, it has to be devel-

oped and written. For many business owners and managers,

the thought and then actions

required to develop and write

the plan is an uphill battle.

If you are one of these peo-

ple, dont feel bad. We find that

only five percent of businesses

have a business plan, and of

those only 35 percent use it to

operate their business. The

starting point is making the

decision to write a business

plan and pledging to actually use it in the day-to-day man-

agement of your business.

There are many helpful books, software packages and

online tools that claim to aid in the development of busi-

ness plans, but it is our opinion that the average person is so

overwhelmed by all the information and tools at his disposal

that he loses track of the key components that a business plan

needs to include.

It is quite simple, and when taken for what it isa planning

toolthe business plan can be written relatively quickly. Lets

look at five essential components of a basic business plan:

1. Define your product/service and your companys value

your value proposition.

2. Define what you sell and what you want to sell.

3. Define why anybody would buy what you sell and why

they would buy it from you.

4. Define the specific people who will buy what you sell.

5. Define your current resources and the future resources

you will need to meet your goalsfor example, people,

skills, technology, machinery, facility, finances, etc.

Defining each of these five essential components is typi-

cally not easy and requires you to really know and under-

stand your business and customers, but it is worth it to take

the time.

The business plan is a critical component of leading a

business, so why not start writing one today? Dont worry

about being perfect or correct at this point, just think and

write. Then speak with your team and start molding your

plan. Before you know it, you will have a new tool that you can

use to manage your business.

The next and most important step is implementation, where

you make it happen. However, this is the area where most own-

ers and managers fail because it requires focus, dedication and

constant follow-up. The majority of owners and managers do

not like these functions and need implementation help, so this

is where seeking out a company that specializes in coaching and

implementing these methods and skills is recommended.

CONTRIBUTOR

Bill Phillips is co-owner of Strategen Inc. and has more than 25 years of expe-

rience in manufacturing organizations. His company is a hands-on consulting

frm that specializes in developing tailored strategies to defne and penetrate

markets, increase margin, and provide the greatest fexibility possible for

technical product and service companies.


Strategen Inc. / 920-980-2347 / strategen1.com

Only fve percent of

businesses have a

business plan, and

of those only 35

percent use it to

operate their business.

Five Essential Components to a Shops Strategic Plan

1113 MMT DEPT--Your Business.indd 10 10/15/2013 2:05:20 PM

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MoldMaking Business Index


to planned shutdowns and vacations,

and less because of weakening market

demand. The production subindex of

52.0 indicates that work levels increased,

as they have for most of the year. With

new orders lower and production levels

up, we should expect a decline in back-

logs. And that is what happened, as the

backlogs subindex eased back to 40.0.

The employment component was exactly

50.0, which means that moldmakers pay-

rolls were steady.

The prices received in the moldmaking

sector were modestly lower in September,

with a subindex of 48.8. The upward

momentum in materials prices acceler-

ated a bit, coming in at 61.8. Supplier

delivery times resumed their recent

trend of gradual expansion, posting a 53.6 in September. The

pace of decline in offshore orders was little changed, with the

exports subindex coming in at 45.3.

Total MBI for September 2013: 48.2

Our latest survey of the North American moldmaking industry

indicates that overall activity levels declined for the third

straight month in September when compared with the pre-

vious month, but the rate of decline is decelerating. The

MoldMaking Business Index for September 2013 is 48.2. The

latest index value is a 3.5-point increase from Augusts 46.1,

and a 0.9-point decrease from 49.1 posted in September 2012.

The index recovered much of the deeper drop-off from last

month, but not all of it. If we look at the bigger picture, the

overall trend all year has been flat to down.

Yet again, there is consolation in the fact that the latest

reading is a contrast to other indicators that measure U.S.

manufacturing levels. The ISM Manufacturing Index in

September posted its highest mark since 2011 with a 56.2.

Demand for autos remained strong. Upward trends in residen-

tial construction and real estate data decelerated a bit recently,

but both are still strong when compared with last year.

The biggest threat to the current economic recovery comes

from Congress. As I write this, the Federal government is in

shutdown, and a vote on the nations debt ceiling is just a few

days away. If these two issues are not resolved in an expedi-

tious and somewhat graceful manner, the effects on the U.S.

economy will be dire. If, on the other hand, Congress and the

President can quickly get us past this debacle, then the pace

of economic expansion will accelerate through at least the

end of 2014.

Taking a closer look at the various categories that comprise

our MBI, the new orders component was 48.4 in September.

This is significantly higher than Augusts reading of 43.6,

and it now appears this weak August figure was largely due

Overall, the trend in the activity levels for U.S. manufacturers continues to exceed

expectations. In fact, if not for the auto sector and the residential construction sec-

tor, the U.S. economy would most likely have entered a recession in 2013. The best

way to describe it is that manufacturing is holding up pretty well this year in spite of

the persistent headwinds caused by lower consumer confdence and weaker global

demand. The trend in our MBI this year has been gradually downward, but the op-

posite is true for many other manufacturing sector indicators in recent months.

There is little to suggest that the recovery will accelerate in the near-term, but the

underlying fundamentals continue to strengthen. House prices are rising, interest

rates remain low, and the employment data are steadily improving. On the consum-

er side, there is pent-up demand for durable goods, while on the business side there

remains a huge amount of cash sitting on the sidelines looking to be invested. All of

the ingredients are in place for a more rapid pace of economic expansion in 2014.

Sub-Indices July June Change Direction Rate Trend

New Orders 48.4 43.6 4.8 Decreasing Slower 2

Production 52.0 49.2 2.8 Decreasing From Decrease 1

Backlog 40.0 41.0 -1.0 Contracting Faster 17

Employment 50.0 50.4 -0.4 Flat Steady 9

Exports 45.3 45.0 0.3 Decreasing Slower 15

Supplier Deliveries 53.6 47.4 6.2 Longer From Shorter 1

Material Prices 61.8 59.3 2.5 Rising Faster 21

Prices Received 48.8 49.6 -0.8 Declining From Flat 2

Future Expectations 69.0 74.8 -5.8 Improving Slower 21

MoldMaking Business Index 48.2 46.1 2.1 Contracting Slower 3

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

3/134/135/136/13

8/13

7/13

9/13

1113 MMT DEPT--MBI.indd 12 10/15/2013 2:03:57 PM

0412 Ingersoll.indd 1 3/12/12 11:00 AM

Profle


Workshop for Warriors:

Fighting for Veterans

Gainful Employment

By Sherry L. Baranek

Workshop for Warriors (WfW), a San Diego-based non-profit

organization, has a single mission: to provide veterans of the

U.S. Armed Services with vocational training, commercially

viable work experience, job placement and an opportunity to

contribute to the community. Several manufacturers and sup-

pliers in the industry have donated CNC and waterjet equip-

ment to this worthy cause, which not only helps veterans find

secure jobs, but helps to alleviate the skilled-labor gap.

WfW founder and CEO Hernn Luis y Prado says that

veterans consistently face significant barriers to employment.

Nationally, the unemployment rate (for veterans) averaged

20.4 percent in 2012almost double the unemployment rate

for the civilian populationand this figure continues to rise,

he says.

CNC machining, welding and waterjet operation are

amongst the industry-specific training options available.

However, Luis y Prado is quick to point out that the organi-

zation also offers mentoring, education and other training

to help veterans transition to civilian life. We provide a

combination of classroom education, vocational training

and work experience that empowers veterans and increases

their career options, confidence and self-respect, he says.

Instruction is offered by skilled veterans, active-duty service-

members and industry experts. Our programs work to

ensure long-term independence and integration of veterans

into the workforce.

In order to provide actual work experience and help vet-

erans move from economic insolvency to self-sufficiency,

Wf W also organizes hands-on tasks that help disabled and

homeless veterans, the community, and local businesses.

Recent projects include fabricating handicap railings, hand-

icap-accessible ramps, metal cylinder pallets and new doors

for a local restaurant. This teaches the veterans necessary

job skills and provides them with a steady income, Luis y

Prado says.

Industry Involvement

Luis y Prado urges the mold manufacturing industry to be

active in Wf Ws efforts. There are three ways that com-

panies or individuals can help a U.S. veteran who will be a

A veteran completes a waterjet training program

and receives a certifcate to be an operator of a Flow

International waterjet system.

Companies like Sandvik Coromant support Workshop

for Warriors with monetary donations.

Workshop for Warriors provides veterans with a number

of training opportunities, including welding.

Phot

os c

ourt

esy

of W

orks

hop

for

War

rior

s.

1113 MMT DEPT--Profile.indd 14 10/15/2013 2:06:37 PM

0513 Schmolz.indd 1 4/5/13 2:22 PM

Profle



Workshop for Warriors

619-550-1620

[email protected]

workshopforwarriors.org

part of Americas new modern manufacturing force: sponsor

a veteran with a donation; let your network of friends, fam-

ily and co-workers know what we are doing; and volunteer

your time. We have an ongoing need for people to help at

the training facility and in our offices, as well as a need for

volunteers who can work from their home for a few hours

each week.

Equipment manufacturers are rising to the occasion with

donations as well. Last January, Flow International Corp.

provided Wf W with a high-speed, high-precision Mach 2c

waterjet system with Dynamic Waterjet taper control, HyPlex

Prime 55,000-psi pump and FlowMaster Intelligent Control

software. Veterans underwent a three-part instructor train-

ing program so they could become certified operators on the

waterjet system.

Haas Automation Inc. also recently

donated four CNC machines to the

organization, which enabled Wf W to

increase its class sizes by 300 percent,

and Sandvik Coromant donated $1

for each recycled pound of carbide it

received. In addition, the Gene Haas

Foundation has offered a match-

ing grant of as much as $100,000 to

increase support of veteran training.

Wf W already can claim significant

achievements. In the past 12 months,

Workshops for Warriors has trained

and certified 90 graduates from weld-

ing and machining classes, Luis y

Prado says. The students have already

earned 157 certificates, and we have a

100-percent job placement rate with

living wages.

We provide a combination of

classroom education, vocational

training and work experience that

empowers veterans and increases

their career options, confdence

and self-respect.

1113 MMT DEPT--Profile.indd 16 10/15/2013 2:06:39 PM

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Case Study / Machining

By Todd Schuett

How can a small, family-owned moldmaker compete in todays

competitive business climate? Strategic investment in high-

technology machinery is the key for South Chicago Heights

manufacturer Do-Rite Die & Engineering.

Do-Rite Die & Engineering specializes in the design and

manufacture of die-casting molds and dies whose end prod-

ucts are for a wide range of industries, including automotive,

medical, lighting, furniture, housewares, appliances, hard-

ware and power tools, agriculture, and industrial equipment.

In addition to traditional high- and low-pressure die casts,

Do-Rite also manufactures tilt-pour permanent molds and

multi-slide tools, also known in the industry as Techmire or

miniature die-casting molds.

Do-Rite has a reputation for its in-house engineering

capabilities, which enable the design to get through mold

manufacturing to the end-

product faster. Clients report

Do-Rites engineering has

also helped them reduce cycle

times while improving part

quality.

Continuous improvement

has been this 60-year-old

shops key to success, espe-

cially through all the industry

changes in the past five yearsnever mind all the changes

since the companys inception in 1953. A newly competi-

tive global business climate has necessitated big changes to

increase productivity while reducing costs, Do-Rite President

Alan Szymanski says. Todays clients enjoy faster delivery

Better Molds

in Less Time with

High-Technology

Machinery

with a new, higher standard of quality from us. The result

is a better value than ever before.

As moldmakers, were constantly improving our skills.

It is one of the attractive aspects of a career in moldmak-

ingwe are learning every day. I like to tell people that

weve been doing the same thing differently for 60 years.

Weve always made die-casting dies, but the techniques

keep improving.

Im really proud of our team of moldmakers, continues

Szymanski. Their pursuit of perfection is crucial to the

reputation that Do-Rite Die has earned over the years.

They have adapted to new equipment and techniques to

build our tools both better and faster.

Technology Breakdown

Investing heavily in new machine technology has given the

Do-Rite team the right tools to compete. Multiple high-

speed CNC machines with sophisticated accessory tooling

Pho

tos

cour

tesy

of

Cre

ativ

e Te

chno

logy

Co

rp.

The impressive results

from the CNC retroft

made it easy to consider

adding another high-

performance machine.

Die-casting mold for shift fork after tryout.

1113 MMT DEPT--Case Study.indd 18 10/15/2013 2:06:59 PM

moldmakingtechnology.com 19

The impressive results from the CNC retrofit made it easy

to consider adding another high-performance machine. In

2011, Do-Rite added a new Creative Evolution CNC model

FMC-1570. This is a larger-capacity high-speed machine

than Do-Rites Mikron HSM-800. With axis travels of 58

27.5 25 inches, the machines work envelope is about

twice the sizequite large as high-speed machines go. The

15,000-rpm spindle has the speed to handle 1/8-inch and

smaller cutters efficiently for contouring, and lots of power

at the low end for roughing with big insert cutters. The Big

Plus BBT-40 spindle design provides extra rigidity for heavy

cuts.

This niche machine, designed specifically for moldmakers,

features high speed combined with high-performance metal

removal. George Nicoloff, president of machine builder

Geonics Inc., says the key is the Creative Evolution CNC

controllers look-ahead features. Look-ahead is a feature

that helps the machine maintain optimal feed rates through

complex contours, he says. This means that even though

the machine program may command the same feed rate

through a complex contour, the machine slows as much

as necessary to maintain accuracy, yet mills at the optimal

programmed feed rate wherever possible. The Creative

Evolution CNC finishes parts faster while maintaining

higher accuracy. Additional benefits are better surface finish

and longer cutter life.

Szymanski supports Nicoloff s claims. When we were

first considering the retrofit, we talked with several other

Die-cast mold assembly in CAD/CAM system. Die-cast part from mold, shift fork.

are at the heart of the formula. In the past five years, Do-Rite

not only bought three new high-speed machining centers,

but also upgraded the control on its graphite electrode mill.

The result is faster, more accurate machining, less benching

and fewer setups.

In 2008, we bought our first true high-speed machining

center, a Mikron HSM-800, Szymanski says. This gave us a

great taste of high-speed technology and what it could do, but

with only one high-speed machine, we often found ourselves

breaking setups to move jobs in and out of that machine as

priorities changed.

In spite of a slow period in 2010, Do-Rite upgraded its

electrode milling capability by updating the control on its

BostoMatic 32GS electrode mill. Updating with the Creative

Evolution CNC control more than doubled our productiv-

ity Szymanski says. The machine runs faster and is more

accurate today than when it was delivered new because of

the new controls look-ahead performance. Today, our elec-

trodes are finished faster and need little or no handwork.

Less handwork means we get more accurate electrodes, more

consistent burns in the EDM, and ultimately, more accurate

and consistent molds.

One of the most important considerations in the decision

to update or to retrofit with the Creative Evolution CNC was

the price. For about one-fourth the cost of a new electrode

mill, we were able to update our existing machine to a whole

new level of performance. That also saved us other costs like

shipping, rigging and retooling, Szymanski says.



Case Study / Machining

companies that use the Creative Evolution equipment. The

consensus was that the Creative Evolution CNC performed

at a level competitive with more well-known brands that

sell at higher prices. This value has proven to be a distinct

competitive advantage. The end result is better parts for a

better looking and more accurate product, all in less time.

Thats a win-win for us and our customers.

One of the most important contributors to its bottom

line is Do-Rites latest addition, a new Creative Evolution

FMC-1060 machine. At roughly 40 24-inch table travels

and with a heavy-duty, 15,000-rpm spindle, this machine

covers the majority of Do-Rites machining needs, and the

Creative Evolution CNCs high-speed performance means

that if a job fits, the company can generally do all milling

operations without moving a job to another machine.

Thats the point, says Ed Szymanski, Do-Rites vice pres-

ident of engineering. The high-speed performance of the

Creative Evolution CNCs, with their ability to take heavy

cuts, means we have fewer setups.

Automated laser tool probing and part probing has made

setups all the easier, too. Tool length offsets and cutter

geometry are set and verified automatically. Heavy steel

blocks can simply be set straight on the table, and the cen-

ter location and top positions are automatically located by

probing. The new machines make setup faster and more

accurate. Whats more, the automation eliminates one more

opportunity for error, our setups.

Summary

The past 10 years or more have shown plenty of change

in the mold industry, and no end is in sight. Continuous

investment in technology is never-ending, Alan Szymanski

says. We have already planned our next purchase for late

2013 and look forward to adding more capabilities to help

us continue to serve our customers with better molds in

less time.


Do-Rite Die & Engineering / 708-754-4355 / do-ritedie.com

Geonics Inc./Creative Evolution CNC

847-608-0700 / [email protected] / geonicsinc.com

Creative Technology Corporation

[email protected] / 847-910-1258 / creat.com

CONTRIBUTOR

Todd Schuett is owner and president of Creative Technology Corp., which

is focused on marketing for manufacturers through photography, video,

website development and writing.

Operator preparing machine program for milling.

Laser probe setting length for tiny, 0.010-inch engraving tool.


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EDM


Wire EDM Goes 3D CAM for Moldmaking Operations

Moldmakers routinely turn to wire EDM to hold incred-

ibly tight tolerances or to create incredibly complex

shapes. However, moldmakers present a unique suite

of specialized needs and face specific challengeswhether

that means increasing taper accuracy on shutoffs and slides,

improving overall surface finish, or achieving better accuracy

on contours and angles.

Over the years, EDM has evolved in many directions to

suit a range of applications and operations, but wire EDM

has recently introduced certain features that specifically lend

themselves to the different types of cuts required by molds,

which brings an EDM machine more into the world of 3D

CAD and solid models than ever before.

Importing 3D CAD

New wire EDM systems allow the importing of 3D CAD

(parasolid) files, and these 3D model contour files are then

extracted via the on-board 3D CAM software. This feature

provides the ability to bring a solid model file into the control

and set the wire cut height to generate the NC cutting profile,

New features, technologies and software make wire EDM well-suited

for tackling solid models, and improving taper angles and surface finish.


By Mike Bystrek

VIDEO

Access video

at end of article.

including machining conditions, and then uses the 2D CAM

software to create the NC program for the machine to follow.

This can also be done in a two-level height setting, which then

generates a four-axis taper profile as required by the model. An

example of this capability is a part with a taper larger than what

the machines U-V travel can handle. The height of the part can

be sectioned into layers to where the angles can be generated.

Dowel locations are then added for proper location for assembly,

similar to a layer cake.

Each layers top and bottom levels can be selected through

the solid model thickness, and the 2D CAM will generate the

shapes at those heights. This process has also been used for

plastic and aluminum extrusion dies that normally start with a

round top opening and progress down through the layers, turn-

ing into the finished part shape, which can be very complicated.

A simple example would be to picture a circle at the top of a

The large taper part shows the high taper guides capability to maintain a

more accurate angle and not cause scraping damage to the wire, making it possible

to attain a 12-micro-inch Ra surface fnish at a 45-degree taper.

1113 MMT -- FEATURE 1.indd 22 10/15/2013 2:08:22 PM


Phot

os c

ourt

esy

of M

C M

achi

nery

Sys

tem

s In

c. /

Mit

subi

shi E

DM.

three-inch thick block with a letter of the alphabet at the bot-

tom. This may need to be split into three, 1-inch thick layers to

provide enough U-V travel to create the required taper angles.

Analyzing 3D Data

This same solid model information is then used by an

advanced programming CNC control, which analyzes 3D data

and recognizes shape characteristics. By analyzing this 3D

data, it establishes all the positions where the height differ-

ences, cavities and interruptions in the workpiece are located.

It will then optimize the machining speed to determine

exactly when and where to reduce power in the transition

areas, thereby eliminating the possibility of wire breaks due to

sudden thickness changes. This enables the machine to per-

form at an optimum

productivity level

with minimal opera-

tor intervention.

An additional ben-

efit of the control fea-

ture is the reduction

of transition marks or

lines when machining through different thicknesses or cavi-

ties in the material. Reducing these lines ultimately provides

a smoother finished surface and reduces secondary polishing

time, which makes for higher-quality components than were

previously attainable.

Enhanced Taper Cutting

Another new wire EDM feature that is well-suited for mold-

making operations is an enhanced taper-cutting system that

consists of special wire guides and software that can create

more accurate taper angles over a wide range of angle changes.

The guides allow the wire to pivot smoothly over a larger

guide radius to achieve the highest-possible precision at any

angle. This benefits surface finish as well, enabling one to

achieve a 12-micro-inch surface roughness (Ra) at angles as


large as 45 degrees and reducing secondary polishing time,

which enables the customer to make the parts less expensively.

When the taper is generated on a wire EDM, the U-V axes

move the upper guide independently from the bottom guide

to generate the angle. This creates a situation where the wire

is pushed to the side, making contact with the side of the dia-

mond insert in the guide. This specific contact location on the

guide radius is known as the angle point of deviation, and it

changes as the taper angle increases.

LEFT IMAGE: Input

material and job

specifcations to

generate NC program

with machining

technology.

RIGHT IMAGE: Import

3D parasolid fle

and set the contour

height for the wire

cut profle.

This photo demonstrates the ability to manage power changes as

to not generate wire lines at the thickness change points, providing a

smooth fnish and reducing polishing time.

LEARN MOREVisit our EDM Zone for more information

about electrodes and wire, sinker and

small-hole EDM.

Go to moldmakingtechnology.com/zones

for a complete list.


EDM


LEFT IMAGE: Set taper angle range and

inspection step increment to begin mapping

deviation points.

RIGHT IMAGE: Set the fve Z heights that control

the taper location through the part thickness.

Z1= top contour height, Z2= half the taper

thickness, Z3= upper guide location, Z4= lower

guide location, Z5= lower contour height. All

these numbers are set from the machine table

height. Z3 and Z4 values are set automatically

from the auto setup calculation and Z-axis

height location.

CONTRIBUTOR

Mike Bystrek is the national wire EDM product

manager at MC Machinery.

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The setup software tracks and stores

these deviation points for a wide range of

angles, and then it automatically adjusts

the machines U-V position to create a

more accurate taper angle. The smooth,

large radius of these guides reduces scrap-

ing on the wire surface, which in turn

helps to produce a much finer workpiece

finish than with standard guides.

Summary

New software technology enables EDM

machines to address the solid operations

common to moldmaking applications

more efficiently and more accurately than

ever before. As such, moldmakers are turn-

ing to wire EDM as a solution for optimiz-

ing productivity, performing precision

taper cuts and providing the best available

surface finishes.

VIDEO: Cylindrical Drive Technology in WEDM http://short.moldmaking technology.com/mitsedm


In its 12th year, the Leadtime Leader Awards,

presented by MoldMaking Technology, honors

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raising the bar in terms of mold engineering,

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Nominate Your Shop Today!

Often we are so focused on the day-to-day activities of running

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want to thank everyone involved in the process.

Jerry Seidelman, Tech Mold, Inc. 2013 Leadtime Leader Winner

For complete information, eligibility requirements and nomination forms,

please visit: short.moldmakingtechnology.com/LLA

or contact Editorial Director Christina Fuges at [email protected] or (800) 579-8809

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Leadtime Leader.indd 1 9/13/13 12:42 PM

Software


Get the Red Out

By Tim Lankisch

Using simulation to predict

high-conductivity insert

performance.

Making Your Move

You can look at this from two angles: cycle time and part quality.

Lets focus on the cycle time aspect first. What would it mean to

your company if you could consistently make molds that outper-

form your competitors molds in terms of cycle time?

Thats a hard one to gauge because you cannot directly com-

pare molds built by two moldmakers. But believe me, molders

will notice. They know what they quoted for cycle time on every

mold, and if your molds can consistently come in under that

number, then you have a leg up on your competition when you

are bidding on future work.

On the part-quality side, the same principle applies: If you can

consistently design and manufacture molds that deliver better

part quality, your customers will take notice, and you will devel-

op a reputation that also puts you ahead of your competition.

Figu

res

cour

tesy

of

CA

E Se

rvic

es.

Do you remember the old Visine commercials from

the 70s, 80s and 90s that showed us how easily you

could get the red out of your tired, weary eyes with

just a drop or two of the product? I dont know why, but I was

wowed by the prospect of being able to make such a dramatic

change in someones eyes with just a couple of drops.

Recently, I was working on a cooling analysis project that

reminded me of those commercials. I started thinking, If only

someone could invent something like that for cooling injection

molds! Just put a couple drops of solution on your hot spots,

and, bingoinstant cooling relief for thousands of cycles. A

boy can dream, cant he? Until this dream becomes a reality

however, well have to stick with what we know, and well use

simulation to get there.

What we know is this: Molten plastic that is injected into

a mold has to be cooled. It must be done uniformly and in a

timely fashion. Otherwise, you are left with not only low-qual-

ity parts, but expensive ones due to longer cycle times. It cant

get much simpler than that, can it?

Unfortunately, for complex shapes, getting that heat out

of the mold is the hard partespecially considering all of the

things that get in the way and make it difficult for a moldmak-

er to use straight-drilled water lines to reach some areas of a

part. These include mold action, ejection, inserts, hot runners,

gating, etc.

Indeed, one of the more-challenging aspects for the mold-

maker to handle is tight geometryareas where there is a deep

pocket between two or more adjacent walls of a part that are

very close to one another. Oftentimes, you either cant get a

straight drill into those areas because of thin steel conditions,

or you dont want to because the drill size would be so small

that the coolant flow would be too restrictive. Its easy enough

for the moldmaker to just let it be, as he doesnt have to live

with the problem day after day like the molder does; however,

any conscientious moldmaker will take the next step and try

to improve the cooling of that area. One way to do that is with

higher-conductivity inserts.

VIDEO

Access video

at end of article.

Original design; no insert.

FIGURE 1

Revised design with BeCu insert added.

FIGURE 2



Both of these ideas are obvious, but what is not so obvious

is figuring out when you should make the move to include

those higher-conductivity inserts. This is where cooling simu-

lation comes in. Using a cooling analysis tool to predict the

differences between a standard cooling design and one using

high-conductivity inserts helps a mold designer make the

decision about whether or not they should be used.

However, as Ive stated in previous articles, the best simula-

tion results come from experienced users who do this kind of

analysis work day in and day out. Experienced analysts will

know how to create an appropriate simulation model with the

proper insert properties so that the results can be trusted.

Accepting all the defaults in the analysis program isnt

always the best choice. For example, experienced users will

know when it is appropriate to use an aggregated mesh solver

and when it is not. They will also know how to interpret the

various cooling analysis results, including when to use part

surface temperatures versus part average temperatures. In a

previous article (MMT, April 2013), we talked about circuit-

ing cooling lines appropriately. The experienced analyst will

know how to do that to get the most out of the water lines.

When performing a cooling analysis, one should go through

the following steps:

1. Determine ballpark cycle time by getting most of the part

to an acceptable temperature for ejection.

2. Evaluate surface temperature uniformity across and

between core and cavity surfaces.

3. Improve hot spots by using direct cooling wherever possible.

4. Introduce beryllium copper (BeCu) inserts in areas where

direct cooling is not possible.

5. Circuit cooling lines for optimal temperature rise and

coolant flow.

Every material has a different temperature at which it is

rigid enough to withstand ejection forces, therefore, the target

temperature for ejection is different for every material. Lets

say were using a polypropylene (PP). We might target an aver-

age wall temperature of around 140F. For a PC/ABS, we might

target 185F. Once most of the part is within +/- 5F of that

target, we should feel comfortable with where weve set the

cooling time.

Dealing with Hot Spots

From there it is an exercise in trying to deal with hot spots in

the easiest way possible, such as moving cooling lines around

until it the temperature is acceptable, or determining whether

more drastic means are necessary, such as BeCu inserts.

The areas with tight geometry mentioned earlier are usually

the ones that demand attention. It is in these areas that we

can start playing what if with BeCu inserts. In the beginning

FIGURE 3

Comparison of surface temperature at same cooling time.

FIGURE 4

Comparison of time to reach the same surface temperature.

Without BeCu Inserts: 202F

With BeCu Inserts: 128F

With BeCu Inserts - 40 sec.

Without BeCu Inserts - 100 sec.


Software


stages of our analysis (see Figure 1), we assume that the whole

mold is made from one material (for example, P20). We assign

thermal properties to it, and no additional geometry modeling

is necessary. However, when we add BeCu inserts, it is neces-

sary to model those inserts explicitly (see Figure 2).

Initially, well put in a generic insert with some rough

dimensions just to see what types of improvements we might

get. Along with modeling the BeCu insert, it is critical that

direct cooling be placed inside it. It doesnt need to be close to

the part surface, but it does need to be inside the insert so that

we dont end up with a block of metal that gets overheated

faster. A BeCu insert that has no direct cooling is thermally

isolated from the rest of the mold, whereas one with direct

cooling provides a path for the heat to get out.

At this point, we run a simulation using the same cooling

time as in the first analysis, and we usually find a significant

drop in temperature (see Figure 3).

Oftentimes, this temperature is well

below that of the rest of the part. If that

is the case, we can now start reducing

the cooling time until the temperatures

in that area start to match the rest of

the part. The result is often a significant

improvement in cooling time. In our

example, it took 60 fewer seconds to

reduce the temperatures in the problem

area to those of the rest of the part (see

Figure 4).

Our example is one of not only

reduced cycle, but improved part quality

as well. In this case, the original cool-

ing design was responsible for 1.0 mm

of the total warpage. By improving the

cooling, the temperature differential

between the two sides of the part was

reduced, thereby reducing the contribu-

tion by the cooling design to the warp-

age to 0.30 mm in the opposite direc-

tion (see Figure 5).

The example weve shown is a fairly

dramatic one for which the benefits are

very clear. When the gains arent nearly

as dramatic, it may boil down to an eco-

nomic decision. In those cases, the ROI

must be evaluated, looking at the total

cost of manufacturing the BeCu inserts

versus the cycle time gains. These costs

LEARN MORE

Visit our Mold Flow and Simulation Zone

for more information on mold fow analysis

software and services, melt management

technologies and strategies, fnite element

analysis, root cause analysis, cooling

analysis, warpage analysis, processing

evaluation, and more.

Go to moldmakingtechnology.com/zones

for a complete list.

At Plastic Engineering & Technical Services, we will.

We produce the fnest Hot Runner Manifold Systems, Valve Gate Sequencers

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include the additional material, along with additional EDM time

and special considerations for handling BeCu.

Summary

So the next time youre looking for a way to improve your molds

with BeCu inserts but are not sure if its worth it, consider using

cooling simulation to help make the decision. Experienced ana-

lysts will be able to tell you not only what kind of cycle time

gains you might expect, but also whether or not you will see an

improvement in the warpage of the part, and that will assist you

and your customers in getting the red out.

FIGURE 5

Comparison of warpage due to cooling effects.


CAE Services / 630-761-9898

[email protected] / caeservices.com

VIDEO: Using Higher Conductivity Inserts for Cooling Tight Spots in Molds http://short.moldmakingtechnology.com/caenov

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Without BeCu Inserts: 1.0mm

With BeCu Inserts: 0.30 mm


Mold Materials


By Robert Kusner and Michael Gedeon

When used in molds, copper alloys offer many advantages

over steel, including improved plastic cooling rates

and less warpage of the molded parts. Companies that

use copper alloys can improve productivity and mold quality

if they recognize the inherent differences between copper and

steel. Here we will focus on the common mistakes that lead to

failure in the application of copper alloys in mold tooling.

Avoid sharp corners.

The most common mistake made in designing a mold, even

those not made of a copper alloy, is making the radii of internal

corners too sharp (see Figure 1). These sharp internal corners

cause a concentration of stress in those areas, leading to prema-

ture fatigue failure and possible impact failure. This becomes

especially important in high-standing cores where the height

of the core exceeds the width by a ratio of 4:1 or more and the

injection pressure is unbalanced. In those areas, an internal

radius of 0.030 inch is recommended. Figures 2 and 3 illustrate

the difference between a good design and a poor design with

respect to these geometric features.

There are two reasons for the occurrence of these failures at

internal corners in copper molds. One is that copper alloys do

not have the intrinsic strength or toughness of steel. Although

the fatigue strength of high-strength copper alloys compares

favorably to some mold steels, they fall short when compared

with the high-hardness mold steels such as H13.

The other reason for these failures is that copper molds are

often used to mold complex geometries with sharp corners and

small dimensions. Inside radii are often less than 0.010 inch

and the height-to-thickness ratio of a standing member often

exceeds 4:1 by a factor of two or more.

High injection pressure is used to help fill these complex

geometries. This higher injection pressure leads to high stress

on the copper mold when it is being filled. After hundreds of

thousands of cycles, fatigue cracking can occur, which ultimate-

ly leads to failure.

These most common mistakes can lead to failure in the

application of copper alloys in mold tooling.

Maximize Results with Copper Alloy Molds

Provide proper venting and parting line protection.

Some resinsnotably polycarbonates and acetalswill produce

combustible gases when melted. When mixed at high injection

pressure with the air of the unfilled mold, these gasses may

auto-ignite or diesel if there is not sufficient venting in the mold

to prevent a pressure buildup. This combustion creates a very

hot and very high-pressure gas that squeezes though the parting

line of the mold, causing a very distinctive erosion pattern in

the mold (see Figure 4). Copper is more susceptible than steel

to these hot, high-velocity gasses since its protective copper

oxide surface is more easily eroded away than a steel surface.

The solution to this problem is fairly simple: improve the

venting of the mold and cover the parting line with a corro-

sion-resistant coating like electroless nickel plating.

Figu

res

cour

tesy

of

Mat

erio

n B

rush

Per

form

ance

Allo

ys.

A crack that formed at a sharp internal corner of a copper alloy mold.

The radius of the corner is estimated to be about 10 microns. A 2,000-psi

unbalanced injection pressure was suffcient to cause this failure.

FIGURE 1



Avoid condensation.

With the superior thermal conductivity of copper alloys, a

copper mold or copper insert will run much cooler than a

steel mold. If the mold is cool enough and the environment is

humid, condensation can form on the mold and cause a poor

surface finish on the molded plastic.

With condensation present, galvanic corrosion can occur at

areas where dissimilar metals are touching. For example, cop-

per inserted in an aluminum mold can lead to corrosion of the

anodic aluminum in the presence of surface moisture. Some

resins (such as PVC) can form corrosive agents like hydrochloric

acid in the presence of moisture, which can corrode the mold.

The solution to condensation problems can be as simple

as reducing the cooling flow rate or increasing the coolant

temperature. A more involved solution would be to design the

mold with multiple parallel cooling circuits so that the cooling

of different areas of the mold can be controlled by adjusting

the flow rate of the appropriate cooling circuit.

Let the heat escape.

One mistake often made when using copper alloys, especially

in slides and cores, is assuming that the mere presence of cop-

per in the mold will remove heat. While copper alloys have

significantly better conductivity than steels (often 5 to 10 times

higher), if heat is not removed from the copper component

by a cooling circuit or a significant conduction pathway (for

example, being bolted to a cooled steel plate), the heat will

build up in the component, leading to high temperature.

In a slide, hoses can be used to direct cooling fluid through

the part. Cores can use bubblers, baffles and heat pipes to aid

in getting coolant near the tip to remove heat. This is illus-

trated in Figure 3.

Use caution when welding.

Copper mold alloys use sophisticated metallurgy to attain their

high hardness. Consequently, it is often difficult to achieve the

same hardness in a weld as in the copper base material, since

the welding process cannot replicate the elaborate heat treat-

ment used to make these alloys.

After welding, both the weld and the metal surrounding

the weld will be softer than the base metal. Performing a

post-weld, age-hardening treatment as prescribed by the alloy

manufacturer may result in some increase in hardness, but the

hardness of the weld and surrounding metal (heat-affected

zone) is likely to remain somewhat softer than the base metal.

If the weld repair is made to an area that does not see high

stress or wear, the service life of the mold should not be affect-

ed if the weld is performed and heat-treated properly. When a

weld is made to fix damage from wear or cracks caused by high

stress, the repaired mold is likely to have limited service life.

Another problem with welding copper alloys is that the

weld will produce significant compressive stress on the sur-

face to which it is applied as the weld shrinks as it cools.

Consequently, the periphery of the weld will be in a state of

tensile stress. These stresses can be high enough to crack the

metal around a weld. To avoid this, welds should be limited in

volume and performed by an experienced welder.

FIGURE 2 FIGURE 3

FIGURE 2: A 3D schematic of a

poorly designed mold insert. These

cores have a high aspect ratio, no

draft and sharp corners at the base.

No cooling circuit has been included

to remove heat from the insert.

FIGURE 3: A 3D schematic of a well-

designed mold insert. These cores have

an acceptable aspect ratio, and the

inside corners have been adequately

radiused. A cooling circuit has been

placed in the insert, which includes a

baffe to direct the fow of coolant up

to the core.

Damage from exhaust gas ignition in a copper core. On the left, a copper

core has exhaust deposits and erosion damage. On the right, the addition of a

thin-dense chrome plating prevented erosion.

FIGURE 4


Mold Materials


Use caution when applying a coating.

Not all coatings are equally effective at protecting the surface of

a copper mold. The improper choice or application of a coating

can lead to softening of the copper alloy or delamination of the

coating. The best option is to find a supplier who has experi-

ence coating the specific mold alloy.

Electrolytic platingssuch as nickel and chromiumhave

been around for a long time and have been shown to be very

CONTRIBUTOR

Robert Kusner, Ph.D. is technical service manager

and Michael Gedeon, applications engineering

manager for Materion Brush Performance Alloys.


Materion Brush Performance Alloys

800-375-4205

[email protected]

materion.com

effective. Nickel provides good corrosion resistance, while chro-

mium provides good wear resistance. Since improper cleaning

will lead to the plating delaminating, the important thing with

these coatings is that they are done by an experienced supplier

who can properly clean the mold.

In the last couple of decades, several vacuum coatings have

been developed for mold tooling. Some of these coatings are

applied at elevated temperatures and are not suitable for all

copper alloys. Many are ceramic and do

not adhere well directly to copper. Much

of the technology for applying these

materials to copper mold alloys is in the

interlayer between the copper and the

ceramic. This is often proprietary, so it

is important to consider not only what

material is being applied, but who is

applying it.

Dont fear copper.

Oftentimes copper alloys are not used

because they are mistakenly believed

to be either too expensive or too weak.

Copper alloys can exceed the hardness

of some mold steels and are mechani-

cally quite suitable to the task. It has

been proven in many applications that

copper can result in molded parts being

produced more quickly and with higher

quality. With some forethought, copper

can be employed in many molds leading

to long and productive runs.

LEARN MOREVisit our Mold Materials Zone for more

information on tool steel, aluminum,

copper, alloys and more.

Go to moldmakingtechnology.com/

zones for a complete list.

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Mold Materials


By Bob Lammon

Today, aluminum tooling offers better quality with less

scrap, faster cycle times, tight tolerances and a consistent

process yielding reduced production costs. These results

demonstrate a technological advancement in the way business is

done in the plastics industry, and the range of possible applica-

tions for aluminum in injection molded plastic devices is limitless.

In todays market there is a momentum toward reshoring

the restoration of manufacturing in Americabut lets take it

one step further by discussing an actual option that not only

influences bringing back business, but is an alternative to steel

tooling that affects how we manufacture.

According to reshoring.org, the mission of the reshoring

initiative is to bring good, well-paying manufacturing jobs

back to the United States by helping companies more accu-

rately assess their total cost of offshoring, and to shift collec-

tive thinking from offshoring is cheaper to local reduces the

total cost of ownership. There are plenty of reasons to reshore,

but there are also many advantages for all domestic suppliers

to consider switching from steel molds to hybrid aluminum

molds from alloys that provide advantages to the bottom line.

Aluminum has been around since it was first developed for

aircrafts in the mid 1930s. The irony is that the 7000 series

of aluminum is good enough to use for the framework on

airplanes and the space shuttle, but is somehow so fragile it can-

not be trusted to make a plastic component. This is primarily

due to misunderstanding about the vast capabilities of this alloy.

Following are some general facts about aluminum tooling:

Aluminum alloys have a Brinell hardness range of 150 to 180,

and a Rockwell hardness range of B82 to B87.

Aluminum machines five to 10 times faster than steel, reducing

finishing costs and lead times between 20 and 40 percent.

Aluminum offers reduced machining time due to thermal and

machining properties, less wear on cutters, fewer electrodes

with faster burn time, and quicker polish times.

Aluminum conducts heat nearly five times faster than P-20 tool

steel, shortening production cycle times by 20 to 40 percent.

Aluminum possesses better thermal conductivity than steel, offer-

ing a more consistent mold temperature, and resin flow equating

to less warpage and higher yields, improving the molding process.

Aluminum delivers critical advantages for OEMs as well, not just

in mold and part savings, but in a faster time-to-market product.

Aluminum tooling can provide millions of shots for products of

unfilled resins, and hundreds of thousands of shots for resins

such as glass-filled.

Surface treatments for aluminum provide protection against

abrasive materials, longer wear life and enhancement of esthet-

ic surfaces.

Critical dimensions and difficult geometries that require lifters

or cam slides and Class A surfaces are just as successful with

aluminum molds as they are with steel.

Aluminum vs. Steel Comparison

Mold Material Thermal

ConductivityDensity Hardness Yield Strength

Coefficient of Expansion

7xxx Aluminum 92.2 0.103 150 - 170 HB 66 -76 13.7

7075 - T651 7xxx Aluminum

75 0.101 150 HB 48 - 73 13.1

6061 - T651 7xxx Aluminum

96 0.098 95 HB 40 - 42 13.1

2618 T6 7xxx Aluminum

102 0.101 95 HB 28 - 30 12.9

P20 Grade Steel Carbon Steel

20 0.285 28 - 36 Rc 130 - 135 7.1

Beryllium Copper 75 0.302 40 Rc 140 - 145 9.7

* Data from Alcoa

CHART 1

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of P

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Within the injection molding industry, a negative perception of aluminum

for anything but prot

Documents

196926-NOV 2013.pdf