Increase Process Security, Minimize Risk

The automotive industry is enjoying a revival. Whether it’s the result of a newfound confidence in the industry or the industry’s shift to standardized, global platforms, automotive is growing. 2015 statistics show that more than 80 million cars and trucks were sold worldwide, and according to IHS Automotive, that number is expected to swell to 100 million in the next four years.

This growth translates into increased demand for quality automotive components from mould and die shops now and in the coming  years.

This growth of the global automotive market requires shorter lead times and a greater focus on quality moulds and components. Whether you are getting your shop into a better position to go after new business or you are looking to keep up with current demand, now is the time to fine-tune your operation to remain as competitive as possible.

This is especially important in today’s highly competitive landscape as OEMs and others along the supply chain have choices in suppliers.

Staying competitive comes down to a few important differentiators: high quality, high productivity levels, and low cost per component. With the proper tools, the right partners, and a secure process, mould and die shops can accomplish all of these competencies.

Boost Quality and Productivity With Adapters

Many automotive moulds and components have difficult-to-reach areas that require tools with long overhang. Because of that long reach, milling operations are prone to vibration. This tool chatter leads to machining security risks, component quality issues, excessive noise levels, poor tool life, and even scrapped components.

For this reason, shops usually use cutting data well below what is possible for the cutting edge, which translates into higher machining costs and longer throughput times.

New dampened milling adapters provide tool reach without compromising performance because of overhang. These adapters have been developed to minimize the negative impact of vibrations that typically occur in long-overhang milling operations.

Multiple lengths of dampened adapters for milling with overhangs range from four to seven times the adapter’s diameter. Reach beyond this range is covered by custom-engineered dampened adapters.

Long-reaching milling adapters allow increases in axial depth of cut (DOC), as well as higher feed rates and faster cutting speeds, which contribute to higher productivity and new possibilities for machining cavities. Using oversized-diameter milling cutters with extended overhang offers a combination of higher productivity and longer tool reach.

Modular Tooling

Shops that perform roughing, semifinishing, and finishing applications that require multiple tools per mould or other component may benefit from a modular tooling or exchangeable-head system because they include a variety of heads, adapters, and shanks that are versatile and productive.

Modular tooling also provides quick and easy indexing, guaranteed repeatability, and reduced inventory.

While it is still necessary to stop the operation to switch to a different tool head, production can start again quickly because the length of each tool meets the exact specification (within 0.002 in.) that is already programmed into the CNC machine.

No additional measuring or programming is necessary. A faster change means a shorter overall stop time. You can also reduce CNC setup time with standardized tool lengths.

Process Security

Modular tooling can improve process security. With each contact point you put your operation at risk for runout, and this is where a system that offers reduced deflection and added stability can help.

Additional features such as a conical thread and tail pilot will ensure that the tool does not move in the holder. Reliable, accurate coupling between the head and shank also is necessary.

The high rigidity of a short tool assembly makes it possible to increase cutting depths without losing stability. Minimal play, better process security, and maximum strength help ensure that quality moulds and components are machined every time.

A modular head system also allows you to reduce your overall inventory because the toolholders can be deployed in diverse tooling combinations to suit specific applications and machine tools. So, a relatively small inventory of standard items is all that is required. For example, a separate precision chuck and cylindrical shank tool can be replaced by a single integrated holder with a modular head interface to reduce tool inventory and costs.

Green Light = Increased Profitability

Productivity is not just about running faster, it is also about knowing how to utilize machines in the smartest way. If you are searching for ways to increase output and get the most value from your expensive machines, you may want to consider lights-out or “green-light” machining.

Green-light machining simply means that when the green light is on, your shop is making money. Conversely, in terms of machine utilization, any time the machine has downtime, the red light is on and it’s costing you money.

We can’t avoid all red lights. Sometimes it’s necessary to shut machines down for setup, tool changes, measuring, and service, but you can minimize downtime by choosing the proper insert grades and geometries, and following a carefully planned process.

Being able to let your machines work unsupervised through the day or night increases productivity. However, in order to run this type of operation, you need to have an optimized, safe machining process that guarantees repeatable, reliable performance.

Size Matters

The larger and more complicated the mould or component is, the more important process planning becomes.

Use your CAM software to its full potential for your milling toolpaths. Good planning will give you considerably shorter machining time, better machine and tool utilization, improved geometrical quality of the machined mould or die, and a better surface finish. Working out all of these details can decrease total production costs.

Also, look for an appropriate insert grade that offers long tool life because of its substrate design, geometries, edge designs, and coating. The material science behind the insert will determine chip control, vibrations, and heat transfer.

Consider cutting tools that are engineered specifically for lights-out machining. For mould and die shops, coated carbide grade inserts should be used for light to heavy milling in unalloyed and alloyed steels. End mills should be solid carbide with optimized geometries for roughing, finishing, profiling, and chamfering.

Although insert wear is inevitable, you can limit and control it by using an insert with a strong edge line, which allows you to run your machines all night and keep them running smoothly without stopping all day.

Brian MacNeil is milling products and application specialist, Sandvik Coromant Canada, 905-826-8900, www.sandvik.coromant.com.