Mazak machining solutions for the Die and Mold industry

Mazak offers 5-axis machines and multi-tasking machines with optimal machine performance for mold processing and adaptation to the latest materials.

Mazak machining solutions for the die and mold industry

 

Molds are used in a variety of products, including body components for automobiles, automotive interior parts, computers, home appliances, PET bottles for beverages, and everyday goods. The production of molds requires high-level metalworking skills to achieve high-precision finishes on various materials such as alloy tool steel, ductile cast iron, and resin.

Mazak offers 5-axis machines and multi-tasking machines with optimal machine performance for mold processing and adaptation to the latest materials. These machines contribute to cost reduction by achieving high-productivity and process consolidation, thereby reducing lead times.

In recent years, there has been an increase in the demand for machining complex-shaped, ultra-precision molds made from diverse materials. Mazak also provides solutions that include processing techniques to achieve rapid and excellent surface roughness finishes.

 

Examples of machining by Mazak 5-axis, multi-tasking machines, and machining centers 

die and mold workpiece beverage spout mold

Beverage spout mold

die and mold workpiece reflector mold

Reflector

die and mold workpiece rubber product mold

Rubber product mold

 

die and mold workpiece industrial machinery parts mold

Mold for general industrial machinery parts 

die and mold workpiece automotive part mold 1

Mold for automotive parts

die and mold workpiece automotive part mold 2

Mold for automotive parts

 

die and mold workpiece 3 to 5 axes machining mold

Mold for general industrial machinery parts by a combination of 3 to 5 axes machining 

die and mold workpiece 5 axis machining mold

Mouse mold by 5-axis machining

die and mold workpiece mirror finished bevel gear mold

Mirror-finished bevel gear mold to reduce polishing process

 

Electric motor spindle for high precision finishing

The electric motor spindle enables high-precision finishing with small-diameter tools required for die/mold machining. By attaching a compact electric motor spindle with automatic tool changer (ATC) capability to the standard spindle, high-quality mirror surface machining can be achieved.

Max. spindle speed: 60000 rpm / 80000 rpm

die and mold electric motor sindle

 

Reflector (mirror-finished)
Size 35 mm × 31.5 mm × 20 mm
Workpiece material STAVAX (52HRC)
Tools Φ2 mm ball end mill
Spindle speed 60000 min-1
Surface roughness Ra 0.05 μm (average of measurements at 3 locations)
Processing time 7 hours 38 minutes

 

die and mold reflector

 

 

Advantages of 5-axis machining

5-axis machining centers allow for continuous multi-face machining, enabling process integration and reducing production lead times while minimizing setup errors due to tool changes.

Shortening the tool protrusion length enables stable and high-precision machining under optimal conditions. The inclination of the workpiece allows for faster tool path velocity, ensuring stable surface precision. 

 

3-axis machining centers

die and mold 3 axis machine tools illustration

Problems with 3-axis machine tools:
Limitations of machining conditions due to tool projection
Decreased surface precision in machining due to zero tool path velocity

Mazak UD-400/5X

die and mold 5 axis machine tools illustration

Advantages of 5-axis machine tools:
Stable machining of deep steps with short tools
Improvement in surface precision by machining at optimal cutting speeds

  

Mazak machine tools used for precision mold manufacturing

 

High-efficiency die and mold machining by Mazak multi-tasking and Mazak 5-axis machining centers

 

Mazak Variaxis i NEO Series

Mazak Variaxis i 700 NEO

Simultaneous 5-axis Vertical Machining Center

The high-performance NEO series with high productivity and low environmental impact technologies

 

Mazak UD-400/5X

Mazak UD 400 5X

High accuracy 5-axis machining center for mold and precision machining

Designed for high-speed micro precision and mold machining

 

 

 

Highly rigid, high-precision vertical machining center series

 

Mazak FJV Series (BT40)

Mazak FJV 250

High-accuracy BT40 double column machining centers

Double column construction designed for high accuracy machining over extended periods of operation