There are three main processes involved in the cutting process of dies.
(1) Rough machining
This is the process of roughly cutting out the product shape.
The surface of the mold is rough because it is machined at high speed.
A round radius tool is used.
(2) Medium finishing process
The steps generated in the roughing process are shaved off.
Radius end mills and, in some cases, round radius mills are used.
(3) Finishing
Finishing is performed to clean the machined surface.
Ball end mills are mainly used.
The percentage of the above work process looks like this
Although the amount of cutting itself is the smallest in the finishing process, it is the most time-consuming machining process.
This is because the cutting conditions are slowed down in order to process the surface cleanly.
If the ball end mill used for finishing is replaced, it will take extra machining time because the blade may chip if the machining speed is forced to be increased.
To improve machining efficiency (shorten machining time), the key point is how close to finish machining can be achieved in the first roughing process. (Fewer steps, clean machined surface, etc.)
In addition, it is also possible to shorten the cutting time in the finishing process by improving the machining procedure.
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