1) choose what mold steels are the most important and most decisive factor?

  Forming method – the basic material from the two types of options.

A) hot working tool steel that can withstand die casting, forging and extrusion of the relatively high temperatures.

B) tool steel cold, it is used for blanking and shearing, cold forming, cold extrusion, cold forging and powder compression molding.

Plastic – some plastics will produce corrosive by-products, such as PVC plastic. Long lay-off caused by condensation, corrosive gases, acids, cooling / heating, water or storage conditions and other factors will cause corrosion. In these cases, recommend the use of stainless steel materials, tool steel.

Die size – large size mold often use pre-hard steel. Hardened steel is often used for the overall small size mold.

Mold using the number of times – long-term use (> 1 million times) of the mold should use high-hardness steel, its hardness is 48-65 HRC. Medium long-term use (100 000 1 000 000 times) Pre-hardened steel molds should be used, its hardness is 30-45 HRC. Short-term use (<100000 times) mild steel molds should be used, its hardness is 160-250 HB.

Surface roughness – Many plastic mold manufacturers interested in a good surface roughness. When adding sulfur to improve metal cutting, the surface quality will be diminished. High sulfur content of steel has also become more brittle.

2) cutting of materials can influence the primary factors?

Steel chemical composition is very important. The higher steel alloy composition, processing more difficult. When the carbon content increases, the decline in metal cutting.

Steel structure of metal cutting is also very important. Different structures include: forging, casting, extrusion, rolling and have been cutting off. Forgings and castings are very difficult to machine the surface.

Hardness affecting an important factor in metal cutting. The more general rule is hard steel, the harder process. High-speed steel (HSS) can be used to process up to 330-400HB hardness of the material; high-speed steel + titanium-based nitrogen (TiN) coating, can process up to 45 HRC hardness of the material; while for the 65-70HRC hardness of the material, then must use carbide, ceramic, metal ceramic and cubic boron nitride (CBN).

Nonmetal doping generally have an adverse effect on tool life. For example, Al2O3 (alumina), it is pure ceramic, has a strong abrasive.

Last one is the residual stress, it can cause problems of metal cutting. Often recommended for roughing after the stress release process.

3) the cost of production mold from which parts?

Roughly speaking, the cost of distribution is as follows:

Cutting 65% Workpiece material 20% Heat 5% Assembly / adjustment of 10%

It is also very clear that a good metal cutting performance and excellent overall solution for the die cutting of the importance of economic production.

4) What is the cutting performance of cast iron?

General, it is: Higher hardness and strength of cast iron, metal cutting, the lower, from the blade and tool life can be expected to lower. The production of cast iron for metal cutting most types of metal cutting its generally very good. Metal cutting and structure related to the processing harder pearlite cast iron is difficult. Flake graphite cast iron and malleable cast iron has excellent cutting properties, and ductile iron is poor. Encountered when machining cast iron

main wear type: abrasion, adhesion and diffusion wear. Mainly by the carbide abrasive, sand casting parameters and hard skin debris generated. BUE bond with wear at low cutting temperature and cutting speed conditions occur. Cast iron ferrite some of the most easily welded to the blade, but it can improve the cutting speed and temperature to overcome.

On the other hand, diffusion wear and the temperature, when produced at high cutting speed, especially when using high-strength cast iron grades. These grades have a high ability of anti-variant, leading to a high temperature. Such wear and cast iron and tool related to the role between, which makes a number of cast iron Xu Yong ceramic or cubic boron nitride (CBN) cutting tools in high speed processing, to get a good tool life and surface quality.

Generally required by a typical processing tool cast iron properties are: high fever hardness and chemical stability, but also with the process, the workpiece and cutting conditions; demands cutting edge with toughness, thermal fatigue and wear and edge strength. Cutting cast iron depends on the satisfaction of how to develop cutting edge wear: Rapid change means that hot cracking and blunt notch Ershi cutting edge premature fracture, broken parts, poor surface quality, excessive ripple and so on. Normal flank wear, balance and sharp cutting edge is generally required to do.

5) What is the main mold, a common manufacturing processes?

Cutting process should be divided into at least three types of processes:

Roughing, semi-finishing and finishing, and sometimes even super-finishing (mostly high-speed cutting applications). Residue in the semi-finishing milling process is of course after finishing the preparation. Processes should be in each of the next process to achieve uniform distribution of left margin, it is very important. If the tool path direction and the work load changes little fast, tool life may be longer and more predictable. If possible, it should be carried out in the special machine finishing operations. This will be a shorter period of time debugging and assembly to improve geometric accuracy and quality of the mold.

6) in these different processes should be mainly what tools to use?

Roughing process: round blade cutter, the ball end mill and a large nose radius of the mills.

Semi-finishing operations: circular blade cutter (range 10-25mm diameter round blade cutters), ball-end cutter.

Finishing operations: circular blade cutter, ball-end cutter.

Residual milling process: round blade cutter, ball mills, vertical mills.

Size by selecting the specific tool, groove and trademark portfolio, as well as cutting parameters and suitable milling strategies to optimize the cutting process, it is very important.

On high-productivity tools can be used, see samples of mold using C-1102: 1

7) In the cutting process have one of the most important factor?

Cutting process one of the most important goal is for each process for each tool to create uniform distribution of allowances. This means that you must use the tools of different diameters (from big to small), especially in the rough