TACKLE THE TOP 5 CHALLENGES OF MOLDMAKING
How mold makers in tool and die shops can work faster while maintaining safety and accuracy INTRODUCTION
Hurry up and wait
Moldmakers are under intense pressure every day. It’s your responsibility to generate trusted numerical That’s why so many moldmakers are investing in control programs that run smoothly and produce automation, allowing software to produce programs accurate, reliable tools. with minimal human intervention. But these tools can’t replicate the unique capabilities that differentiate Management expects you to finish these programs your organization – your work force. Unlocking the while expending as little time and energy as possible. knowledge and expertise held within your team can Of course, they also need you to schedule multiple transform your business, allowing you to meet your overlapping projects so jobs run concurrently, CNC customers’ demands today and in the future. machines get fed continuously, and downtime is minimized. Ultimately, what moldmakers need are reliable ways to generate high-quality NC programs quickly and If you move too quickly and make a mistake, confidently, knowing that CNC machines will perform the results could be catastrophic. Your expensive as expected and the finished tools will meet exacting block of material may be scrapped. An operator could specifications. be injured. An expensive cutter could be damaged. Or the entire CNC machine might break down, damaging Fortunately, there are ways to do this. This ebook the bottom line, the production schedule, and your explores five common barriers to efficiency and how company’s reputation with your customers. to overcome them in your company.
2 | INTRODUCTION TABLE OF CONTENTS
MAXIMIZING SPEED EMPOWERING PEOPLE 01: Pages 4 - 8 04: Pages 20 - 21
MAINTAINING QUALITY 05: NAVIGATING THE FUTURE 02: Pages 10 - 14 Pages 22 - 24
PROTECTING HARDWARE 06: CONCLUSION 03: Pages 15 - 18 Pages 25 - 26 MAXIMIZING SPEED
Specialized software helps tool and die shops make parts faster.
4 | MAXIMIZING SPEED MAXIMIZING SPEED
It may seem obvious, but the number one obstacle to The software should also be able to enhance the efficiency is the speed at which various steps in the model, making modifications to account for shrinkage, moldmaking process can be completed. Accelerating thickening ribs for structural integrity, and separating this work depends in large part on the software used to the component into its core and cavity sides. The application may also be able to help design the whole transform a designed product into a complete mold stack. mold stack, including ejector pins, split surfaces, shutout Ideally, the software you use at the earliest stages can faces, and die blocks, as appropriate. help automate your work at three potential bottlenecks. One of the biggest time savings can occur when software 1. Preparation of geometry automates the design and manufacture of electrodes for electrical discharge machining (EDM). The ability Moldmakers know that a product design is a very to isolate features that need to be sparked and quickly different animal compared with the 3D tool that will be convert them into an electrode form, as well as automate used to make it. One way to speed the transition process rib capping, can save many hours of model preparation, is by automating the analysis and repair of the model whilst also helping to avoid costly human mistakes later when it is first imported. on during the EDM process.
Software that is specifically designed for moldmaking In plastic injection molding, simulation software can applications should be able to import the design and help identify weld lines or air gaps, giving moldmakers pinpoint any problems with the product’s moldability, the opportunity to correct these issues before they cause such as insufficient taper or draft on the sides of the problems downstream. Many applications also facilitate part. Many applications can go further by providing tools optimization, allowing you to change the position of to repair the most critical issues automatically, such gates or other features to ensure the mold works as as filling in missing surfaces, repairing poorly trimmed efficiently as possible the first time. faces, or adding radii to the bottom of deep pockets.
5 | MAXIMIZING SPEED 2. CNC programming
Choosing software with hyper-efficient algorithms can Automation can save a great deal of time as you approach give your company a measurable advantage in speed. the completion of the program. Toolpath editing, for Multi-threading allows all programming steps to run example, makes it faster and easier to make the final faster thanks to developments in computing technology. round of changes by separating the edits from the The ability to create tool friendly CNC strategies, such as calculation. In other words, after the majority of toolpaths adaptive clearing, allows parts to be machined faster and have been calculated, you can continue making edits to more efficiently. While many software providers make delete areas, reorder the path, or change the orientation similar claims about algorithms, ask to see the software in of approach. Then, if you need to recalculate the toolpath action on your parts before making a decision. because you changed a cutter, the software remembers all of these edits and can reapply them if desired. This gives Batch processing of large jobs can streamline operators the flexibility to make the kinds of last-minute programming tasks. The software should be able to apply changes that are necessary on large parts with intricate a series of toolpaths to a part simultaneously, performing features — without the need to sit and wait for the entire the necessary calculations in the background so you can toolpath to recalculate every time you make a change. move on to the next step without having to sit and wait. Many CAM software tools allow these same toolpaths to be saved as templates that can be applied to similar parts in future, allowing you to greatly reduce the time and effort needed to program families of parts.
6 | MAXIMIZING SPEED Utilize batch processing and multi core support for fast calculation on complex geometry
7 | MAXIMIZING SPEED 3. CNC machining
Saving time during machining is all about the moment- to-moment efficiency of the cutter. Software can help with this as well, enabling moldmakers to create NC programs that automatically minimize retractions, especially during roughing. When retractions are required, the software can ensure the cutter lifts away as little as possible and moves to the next point of approach as quickly and safely as possible. All of this allows you to cut less air, reduce wasted movements and shorten cycle times. With Autodesk Software with highly efficient algorithms also makes it PowerMill easier to apply consistent cutter forces and maximize software, Paragon feed rates under different circumstances. If you are D&E, a full machining a part using a solid carbide end mill with service tooling a long flute, for example, you can make more efficient and machining use of the entire flute length by using a deeper cut and company, a smaller stepover. The software should also provide reduced the alternative options for use with large, indexable cutters CAM programming where a smooth, highly efficient path is required. time for its The point is that the software should be sophisticated complex plates enough to recommend these strategies based on from five hours the speeds and feeds you specify, identifying all of to 15 minutes. the ways to run the machine safely with the quickest possible cycle time.
8 | MAXIMIZING SPEED MAINTAINING QUALITY
Increasing efficiency can go hand in hand with optimizing surface finish quality.
9 | MAINTAINING QUALITY MAINTAINING QUALITY
Speeding up the individual steps in tool and die workflows doesn’t pay off if you have to compromise the quality of the tool, and consequently the quality of the molded part. With specialized software for moldmaking, you don’t have to make this tradeoff. Instead, you can take advantage of unique capabilities that improve surface finish while simultaneously making the process more efficient.
Not all toolpaths are born equal
There are many CAM systems on the market and they Toolpath verification tools ensure gouges, collisions or all have differing reputations for creating toolpaths near-misses are identified and removed before they get that are SAFE! Some can create NC code that includes anywhere near the CNC machine tool. random gouges – if left unchecked, this can result in disastrous consequences. For manufacturing molds Quality CAM products with a reputation for creating it’s important to choose a CAM software that has a toolpaths with very high levels of precision and safety reputation for creating toolpaths that are gouge-free, give CNC operators increased levels of confidence to even if the underlying CAD model is imperfect. It is run their machine tools without having to stand and important that the software can tolerate minor defects; monitor the machine. This “lights out” machining frees such as poorly trimmed/overlapping surfaces, gaps up the workforce to tend to other jobs saving yet more or missing features or surfaces that are “inside out”. time and money. High toolpath quality means quality NC code can be produced without having to spend time fixing every single defect, potentially saving huge amounts of time.
10 | MAINTAINING QUALITY On-machine verification
Many shops use scheduled checkpoints to make sure sitting in the correct place on the machine, you can probe an in-process tool — especially a large or complex one it to quantify the misalignment and use the software to — is accurate. It may involve stopping the machine to virtually realign the milling process to match the position measure an aspect of the workpiece with calipers. Or of the actual stock. Doing this avoids the time and effort it may require the operator to remove the part from required to remove and reposition the block on the table the CNC machine and transfer it to a dedicated quality of the machine. Later, you can use OMV data to check control department where coordinate measuring whether the part is actually finished before removing it machines (CMMs) are used to inspect the part. This for final inspection. process is both expensive and time-consuming. In addition, using OMV as a simple “Go” or “No Go” check On-machine verification (OMV) offers an easier and allows operators to verify quality more often and find more data-driven approach to validation. Software potential issues earlier in the process. Problematic parts that supports this capability allows operators to use a can be trapped with the measurement data used to help spindle-mounted touch probe to measure different parts salvage parts before they’re scrapped. OMV can also of the workpiece and validate they are within tolerance, quickly identify parts that cannot be saved, allowing all without removing the part from the machine. them to be scrapped quickly, eliminating the risk of time being wasted with unnecessary machining operations. OMV can save time during initial machine setup, particularly when processing large, or heavy blocks of material. If the material to be machined is not quite
11 | MAINTAINING QUALITY On machine verification checks the quality of the work in process.
MAINTAINING QUALITY | 12 Dynamic Machine Control
Machining large mold tools with deep pockets can be a real challenge. These parts naturally have a higher risk of collisions that involve the machine, cutting tool and/ or workpiece. In order to machine these challenging features, a mold maker may choose to use a three-axis machine with long cutting tools, but this raises the risk of tool deflection or chatter that can reduce part accuracy and surface finish. This option will likely result in parts that require additional finishing, polishing, and rework. A better alternative is to make use of a five-axis CNC machine.
Finding the optimum configuration of a five-axis machine can be a challenging task. Dynamic Machine Control (DMC) uses a “digital twin” of your CNC machine tool to help simplify the programming process. An intuitive drag-and-drop interface allows programmers to manipulate the rotary axes of the machine tool to find the optimum orientation of the machine’s rotary axes whilst also minimizing cutting tool length. DMC also provides instant feedback about collisions, near misses, Optimize cutter or movements that may exceed the travel limits of the lengths, and utilize machine. Essentially, DMC lets you find the optimal shorter cutters orientation so you can minimize cutter length and get a with dynamic higher-quality finish without adding extra time to your machine control process.
13 | MAINTAINING QUALITY Mold simulation and optimization
For plastic injection molding, simulation software offers a third way to maximize surface finish quality. Plastic parts are subject to a number of cosmetic defects that are directly related to choices made when designing the mold.
Simulation gives moldmakers an opportunity to examine these variables and consider all the ways to mitigate risks. You can explore process types to understand how gating choices may need to change if you are using gas assist, coining, two-shot technologies or replacing the pack and hold phase with microcellular foam growth.
In any case, many of these choices can be simulated, creating opportunities to see which one is most appropriate for ensuring the desired level of surface finish quality. The same holds true for exploring material selection, part geometry (such as rib-to-surface ratios), and mold design, in particular gate design. Using software that is specifically designed for moldmaking can give you confidence not only that the mold is optimized but that the final parts will meet expectations in the first shot — without incurring time-consuming rework due Mold simulation to verify quality before to unexpected sink marks, weld lines, splay, or blush. making tooling
14 | MAINTAINING QUALITY PROTECTING HARDWARE
Powerful CAM software should include features that automatically reduce the risk of collision.
15 | PROTECTING HARDWARE PROTECTING HARDWARE
Crashing a tool or machine head is a very expensive, worst case scenario. Collisions are costly to repair, they compromise the safety of CNC operators, and can cause a great deal of downtime. Specialized software can help with this challenge too, allowing shops to increase workflow efficiency without elevating the risk of damaging critical hardware. Model collision avoidance
Protecting multi-million dollar machines starts with the ability to detect when the cutting tool assembly could collide with, or get dangerously close to, the 3D model being machined. Automated analysis tools can quickly identify and resolve potential collisions early in the CAM programming process. This saves time but also gives machine operators the confidence to run programs un- supervised, allowing them to tend to other tasks.
Digital stock models
Because roughing starts from a billet of steel or other material, CAM software needs to account for the presence of the remaining stock at all times. This is typically done with a virtual or digital model of the material being cut. Stock models allow highly efficient toolpaths to be created with minimal time spent machining fresh air. In addition, by understanding the shape of stock at any time, toolpaths can be processed that safely avoid collisions involving the unmachined material and cutting tool assembly. When used in conjunction with 3+2 machining, stock models allow CAM programmers to safely remove material using In summary, digital stock models allow the creation of multiple 5-axis orientations without the risk of milling safe and efficient machining routines with shortened the same area twice. cycle times.
17 | PROTECTING HARDWARE Machine collision avoidance
Automatic collision avoidance is a CAM software feature that helps identify issues within the completed toolpath, such as the risk of a tool holder bumping into the part. Avoiding a collision in the first place is always preferable to simple collision detection.
Typically, the majority of a toolpath is safe but there may be one or two problematic areas. In these cases, the software can smoothly move the rotary axes of the machine tool to avoid the collision. Once the cutting tool is clear of the collision, it can smoothly return to its original tool vector to continue the rest of the cutting pass. Throughout this collision avoiding move, the machine movement should be controlled to avoid any sudden or jerking movements that could result in imperfections appearing in the machined part.
Collision checking the machine with all mold components is important to safety and the reduction of problems that cause downtime.
18 | PROTECTING HARDWARE EMPOWERING PEOPLE
Making life easier for moldmakers and CNC operators streamlines complex processes and gives shops more flexibility to balance workloads.
19 | EMPOWERING PEOPLE EMPOWERING PEOPLE
Empowering people Choosing a single CAM package may also decrease annual training and support costs that would normally People are the core of any tool and die shop. Software be used to make sure every operator is equally is simply the vehicle for allowing experienced proficient within every software environment. professionals to do what they do best. But there are still ways that CAM software can empower the entire Some CAM applications for tool and die shops, moldmaking team to become more productive, make including Autodesk PowerMill, include a variety of fewer errors, and have a better overall experience repeatable features that improve the efficiency of those practicing their craft. manufacturing the mold stack. Templates and macros, for example, enable you to streamline preparatory Consolidating to a single CAM platform is often the first tasks by using proven toolpaths that can be easily step toward higher efficiency, especially in shops that may adjusted to accommodate new parts. They also help be using as many as four or five separate applications. new team members get up to speed more quickly on the unique ways your shop differentiates itself from its Even slight variations in how different software competitors. performs common tasks can limit your shop’s ability to standardize processes and move programs from one Altogether, these time savings give you “breathing machine to the next as workloads dictate. Moving to a room” that can be used to test out new ideas and single platform promotes standardization, so your shop technologies in a simulated environment, or simply can become more flexible in terms of which people work stay up to date on the latest trends and techniques on which jobs, and which jobs run on which machines— that are relevant to your customers and markets. This getting closer to true “lights out” manufacturing. not only creates opportunities to discover new ways to work more efficiently, but it creates a more supportive environment that makes it easier to retain the most talented people.
20 | EMPOWERING PEOPLE Managing on-boarding of new staff
A real problem in the industry is finding skilled workers. As experienced workers near retirement, it is becoming increasingly hard to find skilled engineers to take their place. A good approach sees the more experienced engineers creating a suite of machining “templates” and macros that capture how they manufacture their parts (their “special sauce”). New recruits can use these tools to program the less challenging parts, to become productive more quickly, freeing up the more experienced workers to tackle more demanding (or valuable) projects.
Making life easier for moldmakers and CNC operators streamlines complex processes and gives shops more flexibility to balance workloads.
21 | EMPOWERING PEOPLE NAVIGATING THE FUTURE
Keeping an eye out for new technologies and techniques can improve productivity as well as your competitive advantage.
22 | NAVIGATING THE FUTURE Emerging technologies, such as additive manufacturing (3D printing) offer huge possibilities for mold shops to design and make better parts for their customers
23 | NAVIGATING THE FUTURE NAVIGATING THE FUTURE
Navigating the future Many shops are also exploring additive manufacturing, or 3D printing, to improve efficiency as well. This One of the best parts of the moldmaker’s job is helping technology can be used to create conformal cooling to make interesting, creative, useful, and innovative inserts for parts that are particularly challenging to cool components that fulfill an industry need. One of the with conventional means. More efficient cooling not most challenging parts of the job is figuring out how only helps prevent warpage but also delivers significant to stay ahead of the curve — and the competition — and reductions in cycle time. capitalize on more opportunities to work on the most compelling projects. No matter how you choose to invest in future technology, there are two important points to keep Pushing the envelope of moldmaking is a proven path in mind. First, prioritize investments that are likely to for attracting these sorts of jobs. Customers naturally reinforce your competitive advantages. And second, want to work with shops that are not only skilled in choose software that is specialized for tool and die the fundamentals but can help them understand the work. These applications will be better able to adapt advantages of the latest technologies and practices. to new technology and techniques in the shop without losing any efficiency. For tool and die shops, this raises the question of where to invest. Investing in people is an obvious top priority. Beyond that, however, do you invest in more, different, or bigger CNC machines? Do you invest in new tool shapes for sawing, milling, polishing, and texturing? New PVD or CVD coatings that improve efficiency for machining certain materials? New CNC controller options that are easier or more convenient to operate?
24 | NAVIGATING THE FUTURE CONCLUSION
Final thoughts on preparing your shop to take efficiency to the next level.
25 | CONCLUSION CONCLUSION
Tool and die shops are always going to be battling Get Started to become more efficient. As parts continue to become more complex, materials more diverse, and To learn how Autodesk software can help techniques more specialized, learning how to manage improve efficiency in your tool and die shop, visit all of these variables in a productive way will be a our Solution Hub. constant challenge.
What shops can do is strive to become as efficient as See our Solutions possible. Or, more importantly, become more efficient than your closest competitors. And you can position your shop to build momentum for efficiency through the choices you make today about how to work.
Software is a big part of this conversation. To find the optimal balance between speed and quality, shops need to choose software that is specifically designed to help tool and die shops do just that. Beyond any one platform, it also helps to find a software partner that understands the dilemmas moldmakers face every day and is committed to helping solve them.
26 | CONCLUSION Autodesk and the Autodesk logo are registered trademarks or trademarks of Autodesk, Inc., and/or its subsidiaries and/or affiliates in the USA and/or other countries. All other brand names, product names, or trademarks belong to their respective holders. Autodesk reserves the right to alter product offerings and specifications at any time without notice, and is not responsible for typographical or graphical errors that may appear in this document. © 2017 Autodesk, Inc. All rights reserved.