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With the increasing demand for high-quality parts in the global market, people are becoming more and more interested in seamless welding technologies that can improve the accuracy of parts. Recently, the alliance partner of Makino Japan has successfully developed a new type of seamless welding technology, which can effectively eliminate welds, crossover wires and parting lines between molds. The key to this process is the use of advanced technology and vertical machining centers, which can be used to produce molds in a new way. At the same time, efficient heating and refrigeration cycle technologies are used in the injection molding process. The new technology has not yet been patented, and Makino has developed related processing applications for it.
The use of seamless welding technology not only helps eliminate mold welds, but also improves part accuracy, finish, and appearance observability. At the same time, seamless welding technology has implemented efficient control during the injection molding process, shortening the processing cycle of the mold. Since the product produced by this process has an excellent surface finish, there is no need for secondary sputtering and annealing, which also avoids dimensional changes due to secondary shrinkage. This technology is suitable for most plastic resins and glass fillers. It is particularly suitable for the processing of automotive instrument panels, notebook computer enclosures, televisions, and digital cameras. It is also suitable for large display devices and automotive exterior parts. Processing.
New mold seamless welding technology
In previous mold production processes, cooling lines were placed near the surface of the mold and the surface finish of the product was always not uniform. In some relatively new processes, the quality of the produced product can be better ensured by setting the water flow in the mold core and cavity cooling line near the resin injection area.
The new seamless welding technology uses modern processing machines and some new process technologies. According to the technological requirements of the new technology, in the processing of mesh-like cores and cavities, in order to avoid its movement and secondary clamping, the fourth-axis milling of the machine tool is used, which can improve tolerance dimensional accuracy. Plate fins and water chamber cooling lines have also been used more extensively to further improve product quality and seamless solder finish.
Impact on mold manufacturing process
The advent of new seamless welding technology has made it possible to make a variety of changes in the die channel design and milling operations using a polyhedral vertical machining center. In the actual press molding process, changes in the die channel design can help control the optimal temperature change of the die heating and cooling. By milling the important medium-diameter chamber, temperature fluctuations can be kept within 60°C. These permeation chambers are milled behind the mold cavity. The shape is the same as the mold cavity. It can be used as a channel for high-pressure steam and cooling water. It can play a role in the heat conduction of the mold cavity surface, making the temperature distribution more uniform, thus maintaining the temperature change and controlling. The speed of temperature fluctuations.
The use of a polyhedral vertical machining center with compressed air does not require commissioning time for milling, and as the cycle time is shortened and reliability is increased, the production cost of the mold is reduced. The machining center is equipped with a specially designed clamping and clamping system (rotary smart clamp). With this clamping system, the workpiece can be processed on one side and the mold cavity can be processed on one side only once. The workpiece surface can be alternately and continuously processed and can be indexed efficiently, shortening the processing cycle and delivery time. These characteristics cannot be achieved with a standard horizontal machining center.
The processing system designed by Makino Company first performs indexing on the workpiece at a fixed angle, and then performs corresponding surface processing. Since the workpiece is indexed at an angle and the coordinate values ​​are moved according to the score value, the machining process can be controlled and corrected by the CNC equipment, thus eliminating the CAM software that must be used in the past.
The application of seamless welding technology will not warp and deform the workpiece, nor will it cause any problem for the matching of the mold cavity and mold side mold. In addition, since the workpiece can be tilted, it is possible to avoid using only a ball milling cutter for face machining and extend the service life of the milling cutter.
Die welding technology
Seamless welding technology shows excellent performance in mold welding, improving the accuracy, smoothness and appearance of the parts, shortening the manufacturing cycle of the mold.