How to Machine Demanding Mold and Die Jobs for High-Tech Work

To meet the extremely demanding mold and die machining needs of high-tech industries, GF Machining Solutions LLC (Lincolnshire, IL) has unveiled their new Mikron HSM 500 Graphite high speed mill that combines the features of a dedicated graphite machine with the flexibility of their HSM 500 high speed milling platform. Clad in black paint to denote its specialty, this machine sports an optimized Step-Tec 42,000 rpm spindle, a sophisticated exhaust system, and the ability to quickly switch between wet and dry machining. The unparalleled flexibility of the HSM 500 Graphite ensures that shops can have an all-in-one high speed milling system that allows for wet applications while, at the same time, benefiting from a machine that specializes in graphite applications. Its high-dynamic drives, polymer concrete base and improved spindle allow the machine to hold extremely tight tolerances, such as those required for advanced glass molds and other graphite parts.

“For most applications, the entire process has to be perfect, not just the machine,” noted Dante Payva, a project manager in GF Machining Solutions’ milling division. “Everything must be considered, from the overall shop environment and temperature to the precise measurement of the cutters and process speeds. Our smart machine modules and training programs make that easier than ever even as our machines become more sophisticated.” To that end, the HSM 500 Graphite includes an Operator Support System for automating complex machine setting changes, Intelligent Thermal Control for warm-up time reductions as well as the highest possible accuracy, and an Advanced Process System for on-the-fly control of spindle functions.

This machine is also designed around automation and die-sinking EDM technology to provide users with a complete manufacturing system, making it easy to pair the HSM 500 Graphite with such machines as a System 3R WorkPartner 1+ and an AgieCharmilles FORM P 250. The result is a machine that can reliably and repeatedly provide the highest level of precision at speeds that allow for doubled production capacity and up to 200 percent more profit when compared to competing graphite mills.

In response to the growing demand for reliable high precision in large production runs of complex components, GF Machining Solutions offers the AgieCharmilles CUT 2000 X advanced wire EDM. This extremely accurate machine eliminates pitch and positioning errors that would otherwise result in scrapped parts and increased production costs. Its precise positioning capabilities allow it to hold very tight part tolerances for the utmost in quality and surface finish. The CUT 2000 X is especially well suited to the production of stamping tools and multi-cavity molds for electronics, information and communications applications, and it also excels in micro components for medical applications and watchmaking. With the CUT 2000 X, shops can easily achieve ±0.00006 in pitch accuracy over 13.385 in x 9.050 in and the same for M-shape form accuracy at a maximum metal removal rate of 16.535 sq in/min.

The CUT 2000 X has a third-generation automatic wire changer that automatically transitions between two different wires to both rough and finish parts. This technology eliminates the need to set up and align the machine between roughing and finishing operations, which dramatically improves cycle times and accuracy. The machine’s patented universal 3-point wire guide system handles up to 30 deg tapers. Plus, the guides’ rotatable V-prisms can extend their working lives for thousands of hours, and the same wire guide is used for wire diameters that range from 0.004 in to 0.013 in. The machine’s precision is supported by adapted mechanical structures that ensure high accuracy and high thermal stability, as well as dedicated machine calibration and testing. Stringent factory assembly standards and specific calibration tests ensure this machine’s performance for complex, high precision workpieces.

GF Machining Solutions LLC, 560 Bond Street, Lincolnshire, IL 60069-4224, 847-913-5300, Fax: 847-913-5340, www.gfms.com/us.