Toolmaking 01
Customer request
Injection mold slide to be manufactured as a one-off part by machining, from solid stock.
The component features highly complex geometry on its outer profile and internally it contains a high density of holes and pockets (for cooling, guiding movements and making connections).
Furthermore, the manufacturing process includes hardening, which causes a geometric deformation.
What the customer asked
A different method from toe clamps and dedicated fixtures due to the following usage limitations
Toe clamps: reduced tool access for material removal and longer set-up time
Dedicated fixtures: not cost-effective for one-off production
Avoid using metal foil shims after heat treatment for alignment purpose
Quick clamping and alignment in case of rework
Our solution
High efficiency process in eight stages (including quality control and polishing).
Manufacturing Process Overview
OP 10
Machining:
Roughing till to +3mm and drilling.
Clamping equipment:
Bottom reference Base Gauges M16 and Modular Grip vise.
OP 20
Machining:
Roughing till to +3mm.
Clamping equipment:
Bottom reference Custom Base Gauges M16, Fixed and Support Clamps.
OP 30
Heat treatment:
Hardening.
OP40
Machining:
Finishing.
Clamping equipment:
Bottom reference custom Base Gauges M16 and Adjustable clamps to manage the deformation caused by hardening.
OP50
Machining:
Finishing.
Clamping equipment:
Bottom reference custom Base Gauges M16, Fixed and Support Clamps.
OP60
Machining:
EDM Sinker.
Clamping equipment:
Bottom reference Base Gauges M16 800x800mm, Fixed and Support Clamps.
OP70
Quality Control:
CMM (Coordinate-measuring machine)
Clamping equipment:
Bottom reference Base Gauges M16 1000x400mm and Fixed Clamps.
OP80
Treatment:
Polishing.
Additional Resources
Technical Project Data
- Sector: Toolmaking
- Material Type: Steel 1.2343
- Raw Block overall size: 635x695x452 mm
- Finished Part overall size: 630x689x447 mm
- Raw block weight: 1566 kg
- Finished part weight: 440 kg
- Material removal index (MRI): 72%
- Accuracy: 0,02 mm
Classification Tags
- Material Category: Steel
- Accuracy: High
- Material removal index (MRI): Medium
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