High-Speed Machining Centers Designed for Moldmaking

Hyundai WIA’s all-new Hi-Mold Series of high-speed machining centers were engineered specifically for the machining of precision molds. The HI-MOLD is a high speed bridge-type machining center particularly suited for precision machining due to the bridge design’s high rigidity and the generation of low heat.  The head of the main axis moves up and down and left and right on the cross beam.  The table in turn moves front to rear.  In order to eliminate thermal growth during machining, all axes are driven by high precision double-nut ballscrews. The double pretension design provides outstanding positioning and repeatability with virtually no thermal growth. All ballscrews are connected directly to the servo drive motors without gears or belts, to eliminate backlash.   Rapid high speed axis movement is achieved by the use of linear motion guide ways. This reduces non-cutting time and decreases machining time for greater productivity. Rapid traverse: X/Y/Z axes, 50/50/50 m/min; A/C axes, 70/150 rpm.

The main spindle is designed for high speed and high precision machining at 24,000 rpm with ultra precision class angular bearings providing high speed accel/decel for smooth machining at high rpm’s.  The main spindle delivers little noise and vibration even at the highest rotational speeds, guaranteeing extremely stable machining by minimizing thermal transmisssion to the main spindle. The Hi-MOLD Series has an optional ultra high 40,000 rpm main spindle providing superior quality when machining mold bases and cavities.  Spindle temperature can be controlled by the use of a spindle oil chiller. This ensures constant oil temperature and minimizes growth in the spindle due to heat distortion. Thru the spindle coolant (20, 30, 70 bar) guarantees stable machining and increases tool life by decreasing heat generation caused by high speed machining, particularly when executing deep hole machining.  Spindle taper is HSK-A63, spindle speed is 24,000 rpm (optional 40,000 rpm), spindle output is 33/25 kW, spindle torque is 96/72.5 Nm, and spindle drive is built in.

The automatic toolchanger and magazine are separated by a shutter system which closes during machining, thus keeping chips and fluids clear of the ATC and magazine.  When a tool change is required, machining stops, the shutter opens, the ATC exchanges old tool for new, the shutter door then closes and machining begins again.  The HSK spindle offers users the fastest possible material removal rates, highest accuracy, and rigidity. It guarantees stability when run at high spindle speeds which is excellent for mold manufacturing.  Number of tools: 24 (30 on the Hi-MOLD 750/5A).  Maximum tool diameter: 120/140 mm (20 mm at 40,000 rpm).  Maximum tool length: 300 mm (100 mm at 40,000 rpm).  Maximum tool weight: 8 kg (1.5 kg at 40,000 rpm). Tool selection method: Random.  Tool change time: 2.6 sec.

The revolutionary rotating and tilting table design permits the machining of a wide variety of complex shapes and mold components.  The C-axis rotation is a full 360˚ at 150 rpm and the A-axis is 150˚ at 70 rpm.  Each rotational axis is designed with a with a hydraulic clamping system and roller bearings and results in excellent stiffness and precision.  Tilting angle: +30˚ to -120˚.  Minimum directive angle: 0.001˚. Maximum table load: 250 kg.

Workpiece coordinate values can be set automatically using the optional spindle probe. Tool lengths and diameters can be set automatically using the optional tool setter. Linear scales can be applied when highly accurate positioning is required.

The Hi-Mold Series  offer your choice of advanced CNC controls capable of processing greater volumes of information faster, with increased look-ahead capability — 300 blocks in advance allowing the control to process the data before it is ready to be executed, thus speeding up machining operations — and software specifically written for moldmaking. To define curves and surfaces, CAD/CAM systems employ spline algorithms resulting in very long part programs. NURBS enable both freeform curves and conics to be defined in a uniform manner taking less time to execute. Feed Forward Function reduces the “path following error” by adjusting gain, accel/decel and feed rate while the machine is running. Jerk Control prevents the machine from making sudden shock movements due to accel/decel. Control type: Siemens Sinurmeric 840D or Fanuc 31i-A.

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