![\"\"](\"https:\/\/www.autodesk.com\/products\/fusion-360\/blog\/wp-content\/uploads\/2021\/03\/giant-mold-in-machine-1024x622.png\")
<\/figure>\n\n\n\nAdditionally, many molds will use multiple types of steel in the same tool. To illustrate, if you have a tall boss that might tend to get hot and wear prematurely, mold makers might use a material like H13 as an insert portion of the mold because it will hold up better than standard steel. If you use the same material in the whole mold and that feature wears out, that die or mold is no longer usable.<\/p>\n\n\n\n
When qualities that help improve a material\u2019s performance generally hurt its machinability\u2013often the case with hard materials\u2013how should you proceed and still maintain productivity and quality?<\/p>\n\n\n
Tips for machining hard materials<\/strong><\/h2>\n\n\nFor many manufacturers, machining hard materials seems like trying to finely carve marble with a sledgehammer (nearly impossible).<\/p>\n\n\n\n
You\u2019ll need the perfect combination of several variables:<\/p>\n\n\n\n
\n- A rigid, high-precision tool system<\/li>\n\n\n\n
- Hard and tough tool material<\/li>\n\n\n\n
- Negative rake tool geometry with a high wedge angle, strong shape, and potentially honed at the cutting edge<\/li>\n\n\n\n
- Tool holders with high stiffness<\/li>\n\n\n\n
- Appropriate cutting conditions<\/li>\n<\/ul>\n\n\n\n
The biggest difference when machining normal mold-making materials versus much harder steels and metals is the processing that occurs. In other words, applying the right tools and the right strategy at the right stage in the manufacturing process is an art that you can and should master.<\/p>\n\n\n
1. Gather the necessary tools<\/h3>\n\n\n
You\u2019ll first need the correct tools to machine hard materials. Typically, machinists must choose from three tools\u2013ball end, bull nose, and square end mills\u2013and probably combine them for different stages of the manufacturing process.<\/p>\n\n\n
What is a ball end mill?<\/h4>\n\n\n
First, the ball end mill<\/a> typically serves well for roughing operations, in addition to many finishing operations. A ball end mill has a large radius. This helps dissipate heat and force, enabling high speeds and feeds so you can cut closer to the net shape.<\/p>\n\n\nWhat is a bull nose end mill?<\/h4>\n\n\n
Then, on parts with large, flat floors, you might consider using a bull nose end mill<\/a>. However, due to its smaller radius and poor capabilities for dissipating heat and force, this tool is not ideal as it often leads to chipping.<\/p>\n\n\nWhat is a square end mill?<\/h4>\n\n\n
If the part requires sharp corners where the floor and wall meet, it might call for a square end mill<\/a>.<\/p>\n\n\n\nDry machining with air, or occasionally oil, is often used, as well, as chips are usually smaller and spindle speeds are higher.<\/p>\n\n\n
2. Keep your tools cutting efficiently<\/h3>\n\n\n
As finishing tools wear, they can sometimes be demoted to semi-finishing tools. Some shops will sharpen and re-sharpen old tools, which leads to a need to compensate with\u00a0CAM programming<\/a>\u00a0for the varying cutting edges of a tool. For instance, a \u00bc-inch tool might be used during a cutting process and then get sharpened. The sharpening process actually removes material from the cutter, so you might be left with an obscure tool geometry, like 0.235 inches. Programming then needs to reflect that new cutter to perform operations properly.<\/p>\n\n\n\n
The biggest difference when machining normal mold-making materials versus much harder steels and metals is the processing that occurs. In other words, applying the right tools and the right strategy at the right stage in the manufacturing process is an art that you can and should master.<\/p>\n\n\n
1. Gather the necessary tools<\/h3>\n\n\n
You\u2019ll first need the correct tools to machine hard materials. Typically, machinists must choose from three tools\u2013ball end, bull nose, and square end mills\u2013and probably combine them for different stages of the manufacturing process.<\/p>\n\n\n
What is a ball end mill?<\/h4>\n\n\n
First, the ball end mill<\/a> typically serves well for roughing operations, in addition to many finishing operations. A ball end mill has a large radius. This helps dissipate heat and force, enabling high speeds and feeds so you can cut closer to the net shape.<\/p>\n\n\n Then, on parts with large, flat floors, you might consider using a bull nose end mill<\/a>. However, due to its smaller radius and poor capabilities for dissipating heat and force, this tool is not ideal as it often leads to chipping.<\/p>\n\n\n If the part requires sharp corners where the floor and wall meet, it might call for a square end mill<\/a>.<\/p>\n\n\n\n Dry machining with air, or occasionally oil, is often used, as well, as chips are usually smaller and spindle speeds are higher.<\/p>\n\n\n As finishing tools wear, they can sometimes be demoted to semi-finishing tools. Some shops will sharpen and re-sharpen old tools, which leads to a need to compensate with\u00a0CAM programming<\/a>\u00a0for the varying cutting edges of a tool. For instance, a \u00bc-inch tool might be used during a cutting process and then get sharpened. The sharpening process actually removes material from the cutter, so you might be left with an obscure tool geometry, like 0.235 inches. Programming then needs to reflect that new cutter to perform operations properly.<\/p>\n\n\n\nWhat is a bull nose end mill?<\/h4>\n\n\n
What is a square end mill?<\/h4>\n\n\n
2. Keep your tools cutting efficiently<\/h3>\n\n\n