High-speed Milling and Precision EDM Machining in Mould Manufacturing
Mould manufacturing is an important part of industry, as it plays a vital role in the production of almost all products made for human use. The demands for moulds are increasing, as more and more products require mass production and the moulding methodology needs to be precise and efficient. This is why high-speed milling and precision electrical discharge machining (EDM) are considered as two of the most important modern machining technologies used in mould manufacturing.
High-speed milling is an efficient and accurate way of producing complex shapes and forming geometrical patterns. It is a machining process which uses a rotating cutter to precisely remove material from a work piece. By controlling the speed and feed rate of the machine as well as the type of cutting tool used, the operator can produce detailed and consistent moulds with high levels of accuracy. High-speed milling is often used for specialised components such as gears and cams which have complex profiles, but it is also used for prototyping and rapid manufacturing of moulds. The greatest advantage of high-speed milling is its speed; it can produce intricate patterns which other methods cannot, and at a fraction of the time.
On the other hand, precision EDM is an electrochemical method for machining difficult to machine materials such as tungsten carbide, tool steel and ceramics. By using electrical spark discharges, the material is easily blown away by the highly driven electrical current, creating intricate shapes. In contrast to traditional cutting methods, the process requires no direct contact; instead the machining activity is controlled by the electric voltage and current. This process is very precise, and the surface finish of the moulds produced can be as low as 0.2 micrometers. It can also shape sharp internal angles and cavities to exact dimensions.
High-speed milling and precision EDM are two technologies which are widely used in mould manufacturing. Both methods provide quick, precise and detailed results. The choice of method depends on the specific requirements of the mould and the material type. High-speed milling is suitable for more complex geometries, while precision EDM is the preferred choice for machining hard materials with tight tolerances. As such, both are important tools for the modern mould manufacturer.
