Get Ready for IMTS With These Mold Manufacturing-Focused Exhibits

Single-Source Machine Tool Solutions Associated with Mold and Die Machining

Photo Credit: YCM Technology USA Inc.

YCM Technology USA Inc. presents its latest lineup of application-based machine tool solutions. Complete solutions have been developed for machining characteristics associated with mold and die machining, medical equipment manufacturing, general parts machining, automotive, aerospace, defense and energy applications.

Each comprehensive solution is comprised of best-in-class global machine tool brands and is available exclusively through YCM Technology as part of the YCM Alliance, according to the company. 

High-Speed VMC Offers More Intuitive Machining, Surfacing

Photo Credit: Expand Machinery

Expand Machinery debuts the Genmill VFM-2416 five-axis (4+1) this year. As a high-speed machining system with 2,700 block look-ahead for precise part tolerances — the highest in the industry, the company says — in addition to faster control, moldmakers are able to benefit from more intuitive 3D surface machining and better finishes.

In addition to the general benefits of a full five-axis machine — reduced setups, shorter tooling, improved quality, faster throughputs and the ability to machine more complex workpieces — the Genmill VFM-2416 features a 100-mm zero backlash roller cam tilting rotary table with 360° rotary motion and a swing angle of -20° to +120°.

Horizontal Machining Center Work Envelope Optimized for Cutting Molds

Photo Credit: Okuma America Corp.

The leadership team at Okuma America Corp. introduces the MA- 8000H for the first time in North America, the latest addition to the company’s horizontal machining center (HMC) lineup that has an optimized working enveloped for cutting molds and parts. Okuma says the new CNC machine was designed for greater productivity when manufacturing large parts, without compromising machining capacity, reliability or accuracy.

The MA-8000H HMC is said to be a versatile machine designed for a wide range of machining applications from heavy-duty to high-feed machining. The machine’s work envelope and expansive travel ranges (X-axis: 1,400 mm, Y-axis: 1,200 mm, Z-axis: 1,350 mm), coupled with a highly rigid bed and cast-in ball screw mounts for highly accurate drive and positioning, make the MA-8000H ideally suited to cut medium-to-large workpieces. Additionally, powerful spindle options effectively handle materials across the metal spectrum.

Integrated Manufacturing System Showcases Smart Automation for Mold Builders

Photo Credit: ANCA Inc.

ANCA brings its Integrated Manufacturing System (AIMS), an Industry 4.0 factory-wide integration solution for considering the factory as a single machine rather than separate workflows. AIMS is said to streamline the entire tool manufacturing process and complementary technologies.

The clear benefit of the AIMS for tool manufacturers, ANCA notes, is consistently high-quality tool production that can operate around the clock without reliance on skilled labor across shifts. For mold builders, access to required end mills of various geometries and other cutting tools becomes more flexible and responsive and the tools are of consistently high quality — a factor crucial to this industry.

Laser Welding Workstation Adds to Changing Landscape of Mold Repair

Photo Credit: LaserStar Technologies Corp.

LaserStar Technologies Corp.’s FiberStar 8801 is a state-of-the-art laser welding workstation that workshops across the nation are said to be adopting as their workhorse. The power and precision of fiber laser technology, combined with the utility of a large, adjustable workspace, make this machine the ideal solution for repairing molds.

Capable of output up to 600 watts, LaserStar says the 8801 cuts deep and clean with all the power of an axe — while still offering the accuracy of a scalpel.

Fully Automatic Boring Head Performs Closed-Loop Boring Operations

Photo Credit: Photo Credit: Big Daishowa

The Big Kaiser EWA Automatic Fine Boring System from Big Daishowa  performs closed-loop boring operations without a human operator. This feature eliminates the need to stop the spindle to manually adjust the boring tool, which results in considerable time savings, according to the company. Also, eliminating human interaction reduces cost, improves accuracy and minimizes scrap. The adjustment range of the fine boring head enables the handling of multiple bore sizes with the same tool and ensures a repeatable boring process.

For example, mold bases typically have many bores on the same base for various components, and each bore has its own size and tolerance and requires a unique boring tool to fine bore each hole. The EWA’s automatic adjustment with a large work range means the same tool can accommodate many holes of different sizes and can be programmed accordingly, thus making mold base boring faster, automatic and with less boring tools, Big Daishowa says.

Compact Milling Machine Built to Reduce Cutting Time

Photo Credit: Hurco Companies

Hurco unveils the VM15Di (XYZ travels: 30" x 16" x 20"), which it says combines productivity, technology and value. The VM15Di three-axis machining center reduces cutting times and heat transfer. It boasts a table size of 35.4" x 16", with a table load of 1,500 lbs and rapid feed/cutting feed of 1,417/1,181 IPM. 

The quick and quiet direct-drive spindle and CAT40 Big-Plus tooling is said to provide improved surface finishes. It features spindle speed of 12,000 rpm, with 22.8 HP and 24 ATC stations. These are all mechanical features that benefit mold manufacturing users.

Hybrid Metal 3D Printer Redefines Mold Component Production

Photo Credit: Matsuura Machinery USA

Join Matsuura Machinery to discover the latest in Matsuura’s technological innovations and manufacturing solutions, including the novel MX-420 PC10 five-axis vertical machining center (VMC), the H.Plus-300 PC15 horizontal machining center (HMC), the MAM72-52V PC15 five-axis VMC and the MAM72-70V PC2 five-axis VMC. The Matsuura Lumex team will also be available to discuss the company’s Metal Additive Manufacturing Service Bureau and its production of 3D metal printed and machined parts.

This includes the Lumex Avance lights-out metal 3D printing machines, which produces highly accurate parts — including mold components — from metal powders that are melted and sintered via a laser while surfaces are precisely milled. 

Modular Milling System for Carbide Tool Heads Achieves Maximum Cutting Depth

High-precision toolholder and tool shrinking company, Haimer USA, displays many new high-performance machines at IMTS 2022, now available in Industry 4.0 versions. Haimer will also feature Haimer Mill solid carbide end mills and the modular system, Duo-λock, with new cutting tool geometries for multiple materials, clamping options for milling and turning devices and accessories. 

The Duo-Lock is a modular interface for carbide tool heads. It combines what Haimer reports is the highest accuracy in runout and length presetting with maximum stability based on its pa­tented double cone surfaces, which maintains high stiffness and accuracy due to the third rear contact area for challenging milling applications.

Photo Credit: Haimer USA

Mini Indexable End Mills Deploy High-Density Cutting with Small-Diameter Range

Photo Credit: Ingersoll Cutting Tools

Ingersoll’s new HiPosSFeedV is a “mini-sized” indexable end mill line that is well suited for the small parts and miniature industries, as well as die and mold applications. Since mold builders deals with a diverse range of product sizes — including very small components — the HiPosSFeedV line offers higher density indexable insert cutters in a smaller diameter range from 0.250-0.500" (8-14 mm) and with three different insert styles, enabling mold and die manufacturers to save on cost by replacing more expensive solid carbide round tooling, as well as maintain or increase productivity.

CAD/CAM Software Updates for Mold Design and Manufacturing

Photo Credit: TopSolid USA

TopSolid USA exhibits new updates to TopSolid’Mold, a complete CAD/CAM solution for moldmakers and tool and die specialists that is reported to halve the time taken to design a mold. Grouping together TopSolid’Progress and TopSolid’Electrode integrated modules, TopSolid’Mold covers the complete digital design and manufacturing chain. The software easily works with customer data, easily repairs, adapts and edits data, uses both industry standards and user-designed components, takes into account material deformations and retraction, simulations tool mechanics and more, according to the company.

Hardware Automation, Software and Services Pave the Way Towards Digitalization

Photo Credit: Siemens Industries

Siemens Digital Industries presents its hardware automation and software technology portfolio, highlighted by the digital-native CNC platform, Sinumerik One, for machine tool applications. In addition, Siemens presents its solutions and services for the industrialization of additive manufacturing (AM). In booths #133346 and #433028, the company highlights how machine users can quickly and easily embark on their digitalization journeys — from part concept to design, digital twin to simulation, part and machine production, as well as total integration of these processes into the digital enterprise.

Portable, Flexible Fiber Laser Marker Circumvents Conventional Process Constraints

Photo Credit: Rocklin Manufacturing

Rocklin Manufacturing is exhibiting its portable coating, micro welding and marking solutions, including MobiLase, an all-in-one, portable fiber laser marking unit housed in a 45-lb rolling suitcase. While laser marking units are typically large, heavy, stationary machines, Rocklin says its lightweight MobiLase enables industrial strength laser marking to be taken directly to the part — versus a laser marking station —and completed anywhere. The innovation reportedly eliminates costly downtime and investments in elaborate contraptions to mark large parts.

Fast, Precise and Reliable Touch Probe Systems Target Mold Inspection

Blum-Novotest, a manufacturer of innovative and high-quality measuring and testing technology, is highlighting the Digilog touch probe systems at IMTS 2022. Digilog is said to enable high scanning and probing speeds in the hard-use, high-output molding environments. Complex contours can be monitored in series at up to 2 m/min.

Dililog TC63/64/76 probes provide high-precision digital measurements and lightning-fast analogue scans, according to the company. The probes feature BRC radio technology and are particularly well suited for mold inspection.

Photo Credit: Blum-Novotest

Large Surface Grinders Are 20% More Efficient

Photo Credit: Chevalier Machinery

Chevalier Machinery’s two new surface grinders pave the way to smart manufacturing. The new, larger FSG-2048ADIV and FSG-2064ADIV machines, offering 20% higher efficiency, join Chevalier’s ADIV Series of surface grinders. Consistency in machining accuracy and surface finish, no matter what operator is put on the machine, is of high benefit to mold builders.

The new machines have three features designed to achieve higher efficiency and productivity, according to the company:

• Maximum table speed of 98 fpm (30 m/min) achieved by dynamic hydraulic/lubrication system that cools the spindle, guideways and hydraulic oil;
• Spindle that can withstand heavy-load grinding with six ultra-precision angular contact ball bearings;
• Double-layer casting structure that is said to greatly improve accuracy, rigidity and delivers smooth, stable longitudinal movements.

CNC EDM Sinker Sets Standards for Mold Manufacturers

Photo Credit: Belmont

Belmont Equipment and Technologies says its exclusive Maxicut Series CNC EDM sinker machines have been setting standards and creating solutions for the moldmaking industry since 1994.

The MX-140XW CNC EDM Sinker, featured at IMTS 2022, is characterized by a programmable work tank level that is said to provide excellent operator ergonomics for loading and unloading, while maximizing unattended job operations that have different oil level requirements, the single most important benefit for a mold builder. This sinker is 87" wide x 83" deep, with X, Y and Z travels of 15.7", 11.8" and 15.7", respectively. Available open height is 25.7" and the maximum workpiece weight is 1,760 lbs.

Coarse Pitch Cutter Additions Retain High Tool Rigidity

Photo Credit: Tungaloy America

The TungForce-Rec series presented by Tungaloy America is a versatile shoulder milling cutter featuring V-shaped inserts and positioning on the cutter that enables wider inserts, and thus a higher contact area. The new miniature tool’s clamping system is said to offer exceptional stability when machining small pockets and slots, and is highly rigid, a key benefit for mold manufacturing. Three insert sizes — 04, 06 and 12 —  are available for small-diameter cutters covering a wide application range, including water jacket machining and mold wall finishes.

Gantry Machines Meet Industry-Specific Requirements for Mold and Die Makers

Photo Credit: Zimmerman Inc.

Zimmermann Milling Solutions, a global high-tech supplier of portal milling machines, is virtually showing three new gantry machines at its IMTS booth, including the FZ42, FZ37 and FZ32, all of which are well suited to mold and die making.

Zimmerman says its biggest, double-bridged gantry sets new standards for dynamic roughing while maintaining high precision. The FZ42 CNC gantry milling machine combining work areas of different sizes, travels, milling heads and CNC controls. Regardless of weight and size, the milling process is said to be exact. Furthermore, the gantry design is particularly suitable for the entire range of component machining, according to the company. The structurally rigid center-guiding gantry, cross and Z-Ram and dynamic milling head enable a consistent, efficient milling process. This combination of high thermal stability and rigidity meets industry-specific requirements in tool and die making, aerospace and automotive industries.

Industrial Fiber Laser Solutions for Marking and Traceability

The latest industrial-grade fiber laser marking and engraving technology provides reliable performance, fast cycle times and outstanding flexibility to fit any manufacturing environment — from standalone workstations to production line integration.

Datamark FL Series laser markers from Dapra Marking Solutions offer precise, repeatable, noncontact marking of metals, alloys and most plastics. Available with Q-switched and MOPA-fiber laser sources from 20 to 50 watts, these systems are said to be capable of everything from high-contrast annealed heat marks with no surface disruption to the crisp engraving of both basic text and complex patterns at depths exceeding 0.004".

Photo Credit: Dapra Corp.