Page 5 - Die_and_Molds_User_Guide_7861458_2017

Foreword

A lot of things around us, parts or even fully completed products, are produced in dies and
molds: an internal cylinder block or a toy, a plastic container or a crankshaft, a bottle or a jet
turbine blade, a tin soldier or a boat. These objects differ in their form, material, sizes, mechanical
properties, and are manufactured by different technological methods of metal forming or
processing of plastics.

Broadly speaking a die or a mold, being an assembly unit, comprises various elements, and
many of them are standard or unified. A form of a part that is produced in the die or the mold
is determined by several main components (cavities, rams, etc.).
Shaping the components is a central operation in die and mold manufacturing that demands from
die and mold makers rich knowledge, skills and experience. A die and mold maker is rightfully
considered as one of the most professionally skilled workers in manufacturing. Modern CNC
technology and CAD/CAM systems substantially change die and mold making, turning it from
craft into a whole branch of trade.

A part intended to be produced in a die or mold dictates shape and sizes of the die or
mold and accuracy requirements; and a forming technology and the part run size – the die
or mold material. The part shape and the die or mold material are a source data for
die and mold making. word

Automotive Industry is a major consumer of dies and molds. Approximately 60%
of stamping dies and 40% of plastic molds produce automotive parts.

There are different kinds of dies and molds, which can be grouped in the following principal
types: forging dies, stamping (pressing) dies, die casting dies and molds for plastics.

In manufacturing a die or mold, the shape and the sizes are the main factors of the degree Fore
of difficulty for machining:
• Low degree in case of plane areas, simple shapes, shallow cavities etc.
• Medium, when the shape becomes more complicated, the sizes bigger and the cavities
deeper; rams have steep walls, etc.
• High degree in the context of very complex shape, narrow and deep cavities, considerable
difference between heights, etc.
Also, difficulty in machining is a function of machinability of the die or mold material.

The key to productive and effective die and mold making is the process planning – the choice
of technology of the die or mold manufacturing that, in general, includes machining
operations, assembly and finishing works. Today’s CAD/CAM software enables analyzing the
die or mold design, defining machining strategy, developing CNC programs and machining
simulation in order to find the most efficient solution that allows full use of advantages of
modern machine tools.
The right machining strategy is directly related to correctly chosen cutting tools that
perform material removal during operation. A tool, which seems to be a secondary element
of the die and mold process, is a substantial factor of productivity and profitability.
We, at ISCAR, distinctly understand the role of cutting tools in the die and mold industry and try
to provide the die and mold maker with reliable and efficient tooling that meets every
requirement of the branch. The right tool selection depends on different factors.
We will discuss them here briefly, explain the tools’ features and thus build a base
for the correct tool choice.

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Die and Mold