Publications
Final Report: PSP No.14402-10-02 Improved Manufacturing of MC4531 Mold Bodies Using High-Speed Machining
Document is the final report for PSP project No. 14402-10-02 entitled ''Improved Manufacturing of MC4531 Mold Bodies Using High-Speed Machining (HSM)''. The basic physics of high speed machining is discussed in detail including multiple vibrational mode machining systems (milling and turning) and the effect of spindle speed regulation on maximizing the depth of cut and metal removal rate of a machining operation. The topics of cutting tests and tap tests are also discussed as well as the use of the HSM assistance software ''Harmonizer''. Results of the application of HSM to the machining of encapsulation molds are explained in detail including cutting test results, new tool speeds and feeds, dimensional and surface finish measurements and a comparison to the original machining operations and cycle times. A 38% improvement in cycle time is demonstrated while achieving a 50% better surface finish than required.