The key to the success of the hottest mold worksho

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The key to the success of the mold workshop

today, the mold industry in the United States has experienced considerable changes - largely driven by intensified competition and technological progress. Here is a mold company that organically combines skills and technology, which not only improves its competitiveness, but also surpasses its competitors and continues to grow

as one of the three manufacturing companies under lairam LLC group, Intralox (located in harahan, Louisiana) produces modular plastic conveyor belts. Because there are more than 400 combinations of styles, materials and colors of conveyor belts to be provided, the mold workshop in the company is often at full capacity

today, the mold workshop of Intralox employs 29 mold makers and maintenance technicians to operate 9 surface grinders, 5 milling machines, 3 stamping machines and 2 wire cutting machines. It can be called the most competitive workshop in the region. Helping the company win the competition is the Jung j630-d grinder purchased from United grinding technologies (located in Miami, Ohio), which is equipped with a pa/31 profiler with four diamond measuring points

according to Jules ceccanti, the manager of the mold workshop, the workshop only had the ability of mold maintenance at the beginning of lairam 10 years ago. Then, with the development of maintenance business, it was decided to start the production of cavity mold. With the growth of production capacity, the company has invested a lot in new technologies, and today's mold workshop is the main supplier of plastic injection molds used by the company

"visitors who came here to see our 2015 assembly process and our technical level told us that this mold workshop is one of the best workshops in the southern United States," Mr. ceccanti said

the reason why Intralox has its own mold workshop is self-evident - in order to have the competitive advantage of rapid response to the market, this confidence comes from the consistency of complete process control and product quality, as well as the ability to maintain the owner's mold information and other sensitive issues. "If Intralox wants to purchase molds outside," Mr. ceccanti said, "it will take 18 to 20 weeks of delivery. However, if we do it ourselves, we can complete the processing of molds and produce good products in only 6 weeks."

the workshop does purchase some mold products and send them out. However, some tasks have proved difficult to be handled by other companies. "We used to invite bids for several parts that are now very successful in Jung grinding machine," Mr. ceccanti said. "These parts are very complex, many details, very time-consuming and require high precision. Some companies simply refuse to take over, while others ask high prices, because they are not sure that they can make such parts, or that they can make money."

ceccanti introduced that there were two parts, and the quotation he received was US $1750 per piece. With Jung grinder, his price here is $400 per piece

Shane Jackson, the chief mold technician, listed some reasons for buying j630-d. "Our earlier CNC machine tools can do anything we need, but there are some limitations," he said. The diamond dresser is stationary, which means that the machine tool has to move in X, y and Z axes to use the dressing wheel, which is easy to generate flat points in the future. This kind of flat spot makes the diamond surface wear faster than other parts. When we begin to get irregular diamond wear, the machine operator will try to compensate it, but this compensation is not accurate enough. "

the CNC dresser on Jung grinder can rotate about one axis and allow more control over diamond wear. Mr. Jackson further said that if a part of the diamond starts to wear, you can change the angle of intersection between the diamond and the grinding wheel, so you can avoid the worn part and make more use of the diamond. The rotary four diamond dressers avoid the wear of diamonds, and the Jung grinder allows continuous dressing, so dressing and grinding can be carried out at the same time

Mr. Jackson said that with the original method, he had to draw all the geometry of the grinding wheel, send it through the software program and download it to the machine tool. However, with Jung grinding machine, he only needs to get DXF file from the designer whose average plastic consumption will reach more than 500kg/vehicle, insert j630-d and directly carry out grinding wheel shaping through the file

the built-in grinding wheel library helps fast clamping. Mr Jackson explained that Jung actually "remembered" the shape of the grinding wheel. "You take away the grinding wheel and store it in other places, but the information of the grinding wheel is left in the library of the machine tool. Then when you install the grinding wheel again, you enter a library number, and Jung will know the shape of the grinding wheel used last time. This is a good feature and very flexible. It allows you to interrupt processing, change to one or more new tasks, and then return to the original task. Even if the tasks are separated by a month, there is no complex problem Reprogramming or clamping problems. "

According to Mr. Jackson, Jung is used for the most critical processing in the workshop, and is used to process difficult to machine materials with high requirements for accuracy and surface roughness. As an example of a special core pin groove, a groove with a depth of 0.2000 inches, a width of 0.4000 inches and a length of 12 inches is machined on a cavity blank with a length of 12 inches, a width of 2 inches and a thickness of 2 inches. The typical material is 420 stainless steel or elmax (420, a high vanadium powder metallurgy form equivalent to D2, is one of the most difficult materials to grind). The hardness of 420 is usually HRC, while the hardness of elmax is HRC

once the cavity blank has been milled to the required size, it is placed on Jung. Mr. Jackson will load the grinding wheel geometry, radius and angle, as well as the grinding wheel manufacturer, grinding wheel type, particle size, etc. into the grinding wheel warehouse. Then he can trim the shape of the grinding wheel

"after I finish trimming the shape", Mr. Jackson said, "I will use it to grind the shape of graphite electrode. Then I will pull out the graphite electrode and use traditional means (comparator, display or Zeiss CMM) to check and check the contour or axial range. Usually, we specify the shape accuracy as ± 0.0002 inch. If the graphite electrode is qualified, I know that the geometry of the grinding wheel is correct. Then I will touch each side of the blank, find the center and calculate my position (usually I will program the position and depth) and process the parts. And the parts can get the correct size without any trial cutting. "

"in mold manufacturing, you usually cut some and measure; then cut some and measure again," he said. "As you get closer to the final dimension, you have to measure more and cut less. With Jung grinder, as long as the geometry of the grinding wheel is correct, you can measure it once and process it directly to the final dimension."

the result is significant time savings and improved productivity and flexibility. Mr Jackson cited several examples. Before owning Jung, process four or five typical 8 with four core grooves“ × 10 "cavity takes a whole day. With Jung grinder, all operations including workpiece installation and processing can be completed before noon.

" before use, the finishing of six cavities takes two whole days, 10 hours a day. Now the six cavities can be completed in one day, "Mr. Jackson said. "Save 50% time. That's not Jung grinding faster; we see real competitive benefits from clamping and measuring time."

One of the key problems in mold processing is to have complete confidence in your machine tools (especially grinders). "You have to build trust in machine tools," Mr. Jackson said. "For example, manual machine tools are famous for crawling, and the grinding wheel is very worn, but you don't know where the wear is."

however, he said he was not worried about j630-d and its four rotating diamond dressers. Pa/31 passes through each of the four diamonds (rough diamond, semi finish diamond, finish diamond and spare diamond) when rotating. The cutting depth of the spare diamond is always zero for the machined shape. If there are any flat spots left in the first three strokes, the spare diamond will pick them out

Mr. Jackson said that in order to adapt to today's competition, manufacturers must use semi soft and semi hard products that can provide high production; It is also a machine tool with sound insulation, heat insulation, deformation rate and perfect accuracy. Successful mold workshops must be able to transfer their processing to high-end, high productivity and high-precision technology

in order to adapt to today's competition, manufacturers must use machine tools that can provide high productivity and perfect accuracy. Successful mold workshops must be able to transfer their processing to high-end, high productivity and high-precision technology. (end)

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