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Machining time reduced to one third

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TAIWANESE company Daioku makes complete head, rear and other lights for cars, from making the moulds and producing the components to shipping the finished products for assembly at the automotive manufacturers. Sandvik CoroMill 200 is a versatile tool and is not only suited for use in larger machining centres, which Daioku shows in an operation where a mould is rough milled in an old Makino NC machine." style="WIDTH: 200px;" />

In the mould shop the 43 mould sets were manufactured in 1998; 10 sets for PC moulds, 12 BMC sets, 12 two colour sets and 9 sets for plastic injection moulds.

However, the competition with other manufacturers is hard and Daioku plans to expand their business to other fields, such as the aerospace- and railway industry.

In Taiwan the company has a 90 per cent market share within its field in the automotive industry, but a far more modest figure within the motorcycle area, which also is an area Daioku will try to increase.

To machine the dies and moulds both machining centres and EDM machines are used. However, manual work such as polishing the components takes up a lot of time and this is something all die and mould makers try to minimize as much as possible.

"Some years ago only 30 per cent of the time it took to manufacture a mould was machining time and 70 per cent was manual work. We have invested a lot in CAD-CAM equipment and new machine tools. Now the percentages of manual work and machining time are reversed", explained mould plant vice manager Yu Chih Wei.

"This is not enough and we will invest in a high speed machine and replace some of the older machines to reduce the manual work even further.”

Implementation of new cutting tools is also a factor to enhance the machining performance. One of the real time savers at Daioku is the round insert cutter CoroMill 200. The cutter is frequently used in two Makino machining centres for rough milling of pockets, profiling and face milling.

"We have used round insert cutters for a long time but, it was in August 1998 we started to use the CoroMill 200 cutter and it has worked really well,” Yu Chih Wei says.

“The cutting data could be increased dramatically. With our previous cutter we used a feed speed of 720 to 900mm/min and this could be increased up to 1500mm/min with the 200 cutter, using just 20-25 per cent of the available machine power.

“Since we started to use the CoroMill 200 cutter we have reduced the machining time to one third of what it used to be. We also get a somewhat longer tool life with the new cutter but it was the increased productivity that made us choose the cutter", Yu Chih Wei says.

The particular machining example the cutting data referred to earlier was machining of tool steel with a hardness of 220 HB with a milling cutter, 66mm in diameter. The cutter has four teeth and the feed per tooth is 0.54mm at a depth of cut of 2mm with insert geometry PH in grade GC4040.

Insert grade GC4040 is for tough steel milling operations and is also suited for small batch production in mixed materials. The adhesion between the wear resistant multi-layer coating and tough substrate makes the insert suitable for both dry machining as well as machining with cutting fluid.

The wear pattern of the GC4040 insert is predictable, which gives secure machining and an opportunity to reduce the need for supervision of the operation.

The company was established in 1964 in Taiwan where it is still located. In 1992 Ford Motor Co awarded Daioku as a Q1 preferred supplier. In 1996 Daioku was certified according to ISO9002 and in 1998 they passed both the ISO9001 and QS9000 certification.

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