Milling dies requires adapting the technology to a specific type of material. Hot work tool steel provides very high plasticity while maintaining high resistance of the die to mechanical wear. Dies made of hard, hardened and tempered materials in the range of 45-56HRc – difficult to cut – for hot work used in injection molding, pressure casting and forging processes as well as elements intended for cold work – dies intended for forging or stamping, are improved heat treatment to a hardness of over 60HRC require the use of tools made of sintered carbide during machining, as well as tools covered with hardening coatings. The tools have a varied profile of the cutting part, very often specially adapted, enabling the obtaining of a surface of any shape. The main characteristic properties necessary for machining in the process milling dies are deep pockets and instances having sloping walls, rounded edges and radial transitions between surfaces.
Matrices are technically defined as all parts of a mold that have a hollow shape with a prepared cutout to form the surface of a given element. The term applies to all types of molds used in industry, both in casting techniques, pressing and forging. Matrices are used in most industries, starting from the food industry, automotive, aviation, pharmaceutical industry, ending with coinage. Without the use of matrices, it would not be possible to make commonly used everyday objects.
Due to the nature of the work, matrices must be made of appropriate materials, mainly steel and aluminum alloys are used, but there is also a justified use of magnesium and polymers. Milling matrices for molds, depending on the material used and the degree of complexity, requires the use of machines, tools and software that meet specific requirements.
During the production of prototype dies, aluminum alloys are used as the material. This fact results from lower machining costs, and the prototype verification stages require the introduction of changes and the production of another version of the die. Milling aluminum requires obtaining high cutting speeds, high feeds and ensuring conditions that prevent chips from sticking in the cutting zone. Tools used for milling aluminum dies should be very sharp without hardening coatings and additionally the cutting zone must be well cooled by supplying cooling emulsions.
The complex shape of the surface requires the use of CAM software to prepare the technology of milling the dies. The software for supporting the preparation of machining CAMWORKS has advanced functions for generating intelligent machining strategies dedicated to rough milling of dies.
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