Die and Mold
Molds are used in a variety of products, including body components for automobiles, automotive interior parts, computers, home appliances, PET bottles for beverages, and everyday goods. The production of molds requires high-level metalworking skills to achieve high-precision finishes on various materials such as alloy tool steel, ductile cast iron, and resin. Mazak proposes 5-axis machines and multi-tasking machines with optimal machine performance for mold processing and adaptation to the latest materials. These machines contribute to cost reduction by achieving high-productivity and process consolidation, thereby reducing lead times. In recent years, there has been an increase in the demand for machining complex-shaped, ultra-precision molds made from diverse materials. We also provide solutions that include processing techniques to achieve rapid and excellent surface roughness finishes.
Examples of machining by Mazak 5-axis, multi-tasking machines, and machining centers
Electric motor spindle for high precision finishing
The electric motor spindle enables high-precision finishing with small-diameter tools required for die/mold machining. By attaching a compact electric motor spindle with automatic tool changer (ATC) capability to the standard spindle, high-quality mirror surface machining can be achieved.
Max. spindle speed: 60000 rpm / 80000 rpm
Reflector (mirror-finished)
| Size | 1.38" Ć 1.24" Ć 0.79" |
| Workpiece material | STAVAX (52HRC) |
| Tools | Ī¦0.08" ball end mill |
| Spindle speed | 60000 rpm |
| Surface roughness | Ra 1.97 Ī¼in (average of measurements at 3 locations) |
| Processing time | 7 hours 38 minutes |
Advantages of 5-axis machining
5-axis machining centers allow for continuous multi-face machining, enabling process integration and reducing production lead times while minimizing setup errors due to tool changes.
Shortening the tool protrusion length enables stable and high-precision machining under optimal conditions. The inclination of the workpiece allows for faster tool path velocity, ensuring stable surface precision.
3-axis machining centers
Problems with 3-axis machine tools:
Limitations of machining conditions due to tool projection
Decreased surface precision in machining due to zero tool path velocity
UD-400/5X
Advantages of 5-axis machine tools:
Stable machining of deep steps with short tools
Improvement in surface precision by machining at optimal cutting speeds
Mold repair by wire-arc AM
By incorporating wire-arc metal additive molding capabilities into a simultaneous 5-axis machining center, it becomes possible to streamline the mold repair process and automate the expertise required for skilled mold repair. This enables a one-setup process from cutting to remove the damaged part in need of repair, to metal deposition (AM) processing, and finishing cutting of the layered part.
Process integration of the repair process; one machine, one set-up
- Removal of damaged parts, molding and cutting
- Additive Manufacturing (AM)
- Finish cutting and inspection
Mazak machine tools used for precision mold manufacturing
High-efficiency die and mold machining by multi-tasking and 5-axis machining centers
INTEGREX i-H Series
Simultaneous 5-axis horizontal multi-tasking machine
From turning to 5-axis machining using the Y-axis and B-axis, this machine can handle multiple processes
VARIAXIS i NEO Series
Simultaneous 5-axis Vertical Machining Center
The high-performance NEO series with high productivity and low environmental impact technologies
UD-400/5X
High accuracy 5-axis machining center for mold and precision machining
Designed for high-speed micro precision and mold machining
Highly rigid, high-precision vertical machining center series
FJV Series (BT40)
High-accuracy BT40 double column machining centers
Double column construction designed for high accuracy machining over extended periods of operation
