STUDY GUIDE

Mold Machining
Methods, Part 2
category: Mold / Part Design
course id: rt_1313_us

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 Table of Contents
ABOUT THIS COURSE 4
INTRODUCTION 4
OBJECTIVES 4
DEFINITION 4
CONVENTIONAL DIE SINKER EDM 5
CNC DIE SINKER EDM 8
CNC WIRE EDM 9
POLISHING 10
MACHINING TOLERANCES VS. MOLDED PART TOLERANCES 11
SEAL OFFS 11
TOOLING INSPECTION EQUIPMENT 14
CONCLUSION 15

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 About This Course

INTRODUCTION
“Machining Methods, Part 2” is the third program in the Mold Design and
Moldmaking Series. Before beginning this program, you should have already participated
in the first two programs.

OBJECTIVES
The topics that will be discussed in this program are:

Conventional and CNC die sinker EDM

x CNC wire EDM

x Polishing

x Machining Tolerances vs. Molded Part Tolerances

x Tooling Inspection Equipment

x Seal Offs

DEFINITION
Machining is the removal and shaping of steel in order to produce the base,
inserts, cavity, core and other mold components. Knowledge of various machining
methods is essential for proper mold design and construction of the injection mold.
Without this knowledge, designs could result in requiring excessive machining,
inadequate finishes, unwanted stresses in the steel, or a mold design that cannot be
duplicated.

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 CONVENTIONAL DIE SINKER EDM
Electrical Discharge Machining, referred to as EDM, is a stress-free form of
machining since there is no direct contact between the machining element and the
workpiece. There are three types of EDM commonly used in today’s moldmaking
industry: conventional die sinker EDM, CNC die sinker EDM, and CNC wire EDM.

Conventional die sinker EDM machines use electrodes which contain the detail
that is to be machined into the metal workpiece. Electrodes are made from conductive
materials, such as graphite or copper. The electrode is placed into the machine, a positive
or negative electrical charge is applied to the electrode and the opposite charge is applied
to the workpiece. One restriction of the conventional die sinker EDM machine is that the
burning can only take place in the Z direction.

As the electrode lowers and nears the workpiece, an electrical spark jumps from
the electrode to the metal. This spark burns the metal, and dielectric fluid is used to flush
out the burnt pieces, allowing the electrode to burn uninterrupted until the desired depth
is reached. When the burning is complete, the result is an impression of the electrode in
the metal. The distance between the electrode edge and the burnt metal is referred to as
overburn, or spark gap. Overburn typically ranges from two hundredths of an inch, or
five tenths of a millimeter, down to about two thousandths of an inch, or five hundredths
of a millimeter. Higher voltages and amperages result in a larger spark, therefore
increasing the amount of overburn. To compensate for overburn, electrodes are built
undersized.

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 For example, a one inch, or twenty-five point four millimeter, square is to be
burnt using an overburn of ten thousandths of an inch, or twenty five hundredths of a
millimeter. The overburn of ten thousandths of an inch, or twenty five hundredths of a
millimeter has to subtracted from both sides of the desired one inch, or twenty-five point
four millimeters square. Therefore, the electrode would have to be one inch, or twenty-
five point four millimeters, square minus twice the overburn. The result would be an
electrode of nine hundred eighty thousandths of an inch square, or twenty-four and ninety
hundredths of a millimeter.

If a one-half inch, or a twelve point seven millimeter, circle was desired in the
middle of the square, the circle cut in the electrode also has to compensate for the
overburn. Thus, the circle in the electrode must be larger than the desired circle on the
workpiece. The diameter of the electrode would be the desired one-half inch, or twelve
point seven millimeters, plus twice the ten thousandths of an inch, or twenty five
hundredths of a millimeter, overburn. In this case, the resultant circle within the electrode
would have a diameter of five hundred and twenty thousandths, or thirteen and twenty-
hundredths millimeters. Unfortunately, the deeper the electrode burns, the more it wears.
One way to avoid excessive wear is to build multiple identical electrodes to be used
interchangeably.

Another method is to build multiple electrodes that are designed to perform at

different overburn rates. One electrode is used to compensate for higher overburn rates.
With this electrode, less wear occurs yet a rough surface texture is produced. Two or
three electrodes are designed for lower overburn rates and are used to clean up the rough
surface and to finish off the desired detail.

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 The surface finish left behind from a conventional die sinker EDM machine is
generally rough. Using lower overburn settings improves the resulting surface finish, yet
requires considerably more machining time. Unless the rough EDM texture is desired, the
surface requires polishing. The conventional die sinker EDM machine can achieve
tolerances of five ten-thousandths of an inch, or one hundredth of a millimeter. These
tolerances, however, are dependent on the accuracy of the electrode. Conventional EDM
machines are commonly used for roughing mold cavities and cores, machining hardened
steels and complex geometry such as sharp corners, ribs, small holes, textures and
lettering. This process is also ideal for working on thinner, more intricate workpieces.

Advantages

x complex and intricate detail can be machined

x no stress is applied to the workpiece

Disadvantages

x multiple electrodes must be built

x the accuracy of the process relies heavily on the electrodes

x extensive polishing is required for a smooth finish

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 CNC DIE SINKER EDM
The CNC die sinker EDM machine is an extraordinarily versatile machine. This
machine operates under the same principles as the conventional die sinker EDM machine,
but is equipped with a computer to control burning in the X, Y, and Z axes. The
advantage to full 3D movement is that the machine can also perform Loran functions.
Loran functions allow the electrode to move in a pattern perpendicular to the direction
being burnt. The CNC Loran patterns typically move in circular, square, or spherical
patterns to help smooth out the rough surface. These patterns can produce a near mirror
finish if a highly polished electrode is used.

The computer compensates for the difference between the undersize and the
overburn using the Loran function. This lowers the amount of wear on the electrodes and
allows for the same electrode to be used under various burn settings. This example uses
the same electrode to burn the cavity with high overburn settings, and smooth out the
rough texture using low overburn settings and a Loran pattern.

Many CNC die sinker EDM machines are available with automatic tool changers,
allowing the machines to run for hours unattended. The CNC die sinker EDM can reach
tolerances of one ten thousandths of an inch, or two thousandths of a millimeter. This
process can be used for machining detail on cores, cavities, inserts, and most mold
components.

Advantages

x near mirror surface finishes

x minimal operator attention

x fewer electrodes are needed

Disadvantage

x machinery is much more expensive

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 CNC WIRE EDM
CNC Wire EDM is a form of electrical discharge machining that uses an
electrically charged copper wire to burn away metal from the workpiece. A spool of wire
is threaded over tensioners and guides and then either through or next to the workpiece,
where an electrical spark is created and burns the designated path. As with all CNC
machines, simple cutting paths are programmed manually and more complex paths
programmed using CAM software.

Since the copper wire is very thin, it often breaks, requiring it to be re-threaded.
Many newer machines are self-threading, allowing it to run for several hours unattended.
Some of the more advanced wire EDM machines are capable of angling the wire over
forty-five degrees. This allows the machine to cut drafted and complicated holes and
contours.

The wire EDM process is a stress-free machining method, making it ideal for
machining thin mold components, such as ejector pins, long cores, and electrodes.
Resulting surface finishes vary depending on the overburn settings used. As in die sinker
EDM, overburn is the distance between the cutting tool, in this case, the wire, and the
workpiece. Although higher overburn settings provide faster machining times, the surface
finish is typically rough and requires extensive polishing. Lower overburn settings are
much more time consuming, yet can produce near mirror finishes.

CNC wire EDM machines can reach tolerances as tight as one ten thousandth of
an inch, or two thousandths of a millimeter. The CNC wire EDM process is commonly
used for machining die sinker EDM electrodes, thin mold components, ejector pin holes,
contoured and drafted cores, cavities, pockets and profiles.

Advantages

x ability to machine accurate holes

x ideal for machining deep cavities and pockets

x stress free machining

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 POLISHING
Polishing is used solely as a finishing operation. Polishing involves smoothing out
a surface using stones or compounds. Most polishing operations are very time consuming
and require a great deal of skill and experience. Polishing stones come in a variety of
textures, ranging from coarse to extra fine. Coarse polishing stones are used primarily at
the start of the polishing stage and remove machining marks as well as rust or any other
surface defects. Extra fine polishing stones can provide a fairly smooth surface, which is
suitable for most applications.

Polishing compounds are used to create a highly polished, mirror finish, known as
an A1 finish. Polishing compounds contain small particles of abrasive materials such as
diamond and stone. These compounds are applied to the surface with a non-abrasive
medium such as cotton, felt, or wood.

High-speed rotary, vibrating, and reciprocating machines can be purchased to

minimize the time and strain of the polishing process, and also to improve the desired
finish. Polishing is a very common finishing operation. Polishing can be used to smooth
any surface, from a roughed pocket to a ground surface.

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 MACHINING TOLERANCES VS. MOLDED PART TOLERANCES
During the injection molding process, plastic material does not shrink
consistently. With this in mind, the machining tolerances must be tighter than the molded
part tolerances. Machining tolerances should be one quarter or less of the molded part
tolerance. For example, if the tolerance on a given molded part was plus or minus eight
thousandths of an inch, or two tenths of a millimeter, then the tolerance for the machined
mold cavity has to be at least plus or minus two thousandths of an inch, or five
hundredths of a millimeter.

Many of the newest machining centers can accomplish tolerances of up to five

decimals in inches and four decimals in millimeters. The tolerances need to be calculated
and reviewed before the mold making process begins; to determine whether or not they
can be achieved. It is very difficult to maintain tight tolerances for large parts since
variations in material shrinkage multiply as part dimensions increase.

In order to produce an acceptable part, a tool may be built ‘steel safe’. Steel safe
refers to leaving additional metal on the tool, so that if adjustments need to be made, the
metal can later be removed. The molding process is a complex relationship involving
factors such as filling, packing, cooling and material properties. For this reason, it is often
necessary to make changes to the mold in order to produce acceptable parts. Steel safe is
commonly practiced for the simple reason that it is easier to remove metal than it is to
add it back to the mold.

SEAL OFFS
During injection molding, most plastic materials can flow through areas thinner
than one thousandth of an inch, or two hundredths of a millimeter. Silicone and liquid
crystal polymers can even flow through spaces as thin as two ten thousandths of an inch,
or five thousandths of a millimeter. Even very small gaps between mold components can
produce flash, which is the unwanted excess polymer found on the edges of a part. To
prevent flash from occurring, the two halves of the injection mold must be either sealed
off or shut off.

The simplest and most common form of seal is the butt seal. This consists of two
flat surfaces that meet perpendicular to the direction of closure. This seal is extremely
effective because the clamping force is applied directly to the parting line.

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 The angular seal is used to shut off at an angle. When using an angular seal, the
corners must meet exactly. If the angles do not properly seal, the whole angled surface
can flash. When designing an angular seal, it is important to consider the machining
method to be used. For example, if a ball endmill is used to machine both of the mating
surfaces, the corner radii cannot be less than the radius of the ball endmill.

In order for a radius seal to work correctly, the radius on both sides must be equal.
Inconsistent radii can result in unwanted gaps which can flash or wear prematurely. The
most complex form of shut off is a contour seal. Contoured parting lines require the use
of CAM software and are machined using CNC milling, wire, or die sinking EDM.

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 A spotting press can be used to check the parting line. This is a large hydraulic
press that opens and closes the mold. Spotting fluid is placed on the parting line and the
mold is closed under pressure. Areas where the spotting fluid transferred from one half to
the other are areas where the parting line is shutting off successfully. A parting line
mismatch exists in areas where the spotting fluid does not transfer from one side to the
other. If the parting line has areas where it is not sealing off, then there are different ways
to fix it.

One method is to adjust the parting line on the computer file and re-cut the parting
line using CNC milling, die sinker or wire EDM. Manual grinding tools can be used to
grind down areas that prevent the mold from shutting off. This method can be fast, but
requires an experienced mold maker to prevent damage to the mold.

Lastly, the core and cavity blocks can be placed into the EDM machine and one
block can be used as an electrode for the other. This compensates for variations between
the seal off of the core and cavity blocks. This method cannot be applied to molds that
have high angled parting lines or a high radius shut off.

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 TOOLING INSPECTION EQUIPMENT
Tooling shops use inspection equipment to verify the quality of their work.
Calipers are simple measuring devices and can be used to measure the inside, outside, or
the depth of the subject. Calipers have an accuracy of plus or minus one thousandth of an
inch, or two hundredths of a millimeter. Calipers are used for rough measurements and
are not recommended as a final inspection tool.

Micrometers are more precise, and can measure with an accuracy of one ten
thousandth of an inch, or two thousandths of a millimeter. These devices are available as
outside, inside, step, depth and height micrometers. Bore gages are used to measure the
diameter of a hole. These also measure to plus or minus of one ten thousandth of an inch,
or two thousandths of a millimeter. Height gages measure the height of an object and
have an accuracy of plus or minus one thousandth of an inch, or two hundredths of a
millimeter. More advanced height gages include digital readouts and touch sensors that
can improve the accuracy to one ten thousandth of an inch, or two thousandths of a
millimeter.

Optical comparitors magnify an image and project it onto a screen. This can either
be a detailed image or a silhouette of the object. The comparitor uses a table, which
moves on both the X and Y axes. The operator visually aligns the image with a point or
line on the screen, and then measures the movement by graduations on the handles of the
table. These comparitors can be used to measure objects with an accuracy of one ten
thousandth of an inch, or two thousandths of a millimeter, without actually touching the
piece being inspected. Various overlay screens are available for comparitors to measure
angles, radii and screw threads. The comparitor is very useful for measuring workpieces
and cutting tools used for CNC applications.

One of the most accurate measuring devices used in moldmaking is the

Coordinate Measuring Machine, or CMM. These devices are interfaced with a computer
and use touch probes that initiate measurements. The CMM can measure in all three axes
and is accurate up to five hundred thousandths of an inch, or one thousandth of a
millimeter. These systems can be used to measure lengths, widths, diameters, surfaces,
angles and flatness. Many tool shops add a video camera to the CMM measuring head to
take measurements without contact. The crosshairs on the video screen are aligned with
the object being measured. This can only be done for measurements in the X and Y
directions since the camera can not accurately perceive depth.

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 CONCLUSION
Tooling shops tend to specialize in certain areas, therefore we recommend that
you visit different shops to see their equipment and to get a feel for their tooling methods,
and their techniques.

After finishing this program you should have a better understanding of:

x Conventional and CNC die sinker EDM

x CNC wire EDM

x Polishing

x Machining Vs. Molded Part Tolerances

x Tooling Inspection Equipment

x Seal Offs

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