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How are precision moulds made?

Date: 2024-12-3
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In the vast field of manufacturing, precision moulds play a vital role. Not only are they key tools in the production of high precision parts or products, but they are also an important guarantee of product quality and consistency. So how are precision moulds made? This article will unravel the mystery of the process.

The manufacture of precision moulds begins with the selection of raw materials. Commonly used raw materials include metals (such as aluminium alloys, copper alloys, steel, titanium alloys), ceramics (such as alumina, zirconia, silicon carbide) and plastics (such as polypropylene, polystyrene, polyimide). These raw materials have their own characteristics, such as the high hardness of metals, the heat resistance of ceramics and the ease of processing of plastics, which enable them to meet the manufacturing requirements of different moulds.

Once the raw materials have been selected, the next step is to design and process the mould. The design stage requires the use of advanced computer-aided design (CAD) and computer-aided manufacturing (CAM) technologies to ensure the accuracy and complexity of the mould. The machining stage includes a variety of processes such as milling, wire erosion, EDM, grinding and turning.

Milling is a common process in mould making. It uses a rotating tool to cut the raw material into the required shape and size. With the advancement of technology, from the original ordinary milling machine to the three-axis machining centre and then to the current five-axis high-speed milling technology, the milling process has been able to achieve efficient machining of complex three-dimensional surface parts.

Wire EDM is mainly used for machining two and three dimensional straight grained surface parts and occupies an important position in mould making. In this process, the workpiece material is gradually removed by the discharge between the fine wire electrode and the workpiece to achieve the required shape and precision.

EDM is an ideal choice for machining complex shapes, narrow gaps, deep cavities and other parts of the mould. When traditional cutting tools cannot reach these complex surfaces, EDM shows its unique advantages.

Grinding is the key equipment for finishing the surface of moulded parts and is particularly suitable for machining hardened workpieces. Through the rotation of the grinding wheel and the movement of the workpiece, the grinder can precisely grind the surface of the mould parts to achieve the required surface finish and precision.

Turning is mainly used to process various rotating parts. With the development of CNC technology, turning machining has achieved efficient machining of complex rotating body shapes and is widely used in mould manufacturing.

During the mould making process, many measurements and inspections are required to ensure the accuracy and quality of the mould. Precision measuring instruments, such as coordinate measuring machines and vision measuring systems, play an important role at this stage. They can accurately measure the size, shape and positional relationship of the mould, and provide accurate data support for subsequent processing and troubleshooting.

In summary, the production of precision moulds is a complex process involving many processes and technologies. From the selection of raw materials to the design and processing of moulds, to measurement and inspection, each link requires strict control and fine operation. Only in this way can precision moulds with high accuracy, complex shapes and subtle details be produced, thus providing strong support for the development of the manufacturing industry.

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