Precision Mold Machining Solutions for Diverse Industries

Advanced Mold Machining Applications and Case Studies

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Vision Wide offers a wide range of high-precision machining solutions tailored for mold manufacturing across various industries. Below is an organized showcase of real-world applications, highlighting the machining processes, materials, and results achieved with our technology.

Automobile Light Mold

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• Model: ASM
• Material: 2311 Die steel
• Size: L360 x W160 x H360mm
• Linear project cutting with multiple inclined planes and oblique angle cutting to enhance machining efficiency.
• Surface roughness: Ra 0.4µm
• Contour accuracy: 0.04mm

Headlight Mold

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• Model: SE / GS / GSF
• Material: P20 Die Steel
• Size: L800 x W550 x H250mm
• 0.2G high acceleration mold finishing.
• D25 high feed rough machining: F10,000 mm/min.
• D10R5 high speed surface finish: S12,000 rpm, F4,000 mm/min.
• Surface roughness: Ra 0.4μm
• Contour accuracy: 0.04 mm

Bumper Mold

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• Model: SF
• Material: FC300
• Size: L1,000 x W400 x H350mm
• Long spindle nose enhances tool rigidity and reduces cutting vibration.
• D20R10 ball end tool reciprocating projection machining, pitch 0.5mm.
• Spindle speed: 12,000 rpm
• Feed rate: 5,000 mm/min

Automotive Reflector Light Core

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• Model: SE/GS series
• Material: NAK80 die steel
• Size: 160 x 160 x 100 mm
• Surface roughness: Ra 0.4μm
• Contour accuracy: 0.02 mm
• D3R1.5 ball end machining
• Spindle speed: 12,000 rpm
• Feed rate: 1,500 mm/min

Headlight Cavity Finishing

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• Material: Alloy steel
• Size: L151mm x W105mm x H155mm
• Surface height difference: 103mm
• Surface roughness: Ra 0.8 mm
• Long tool machining (tool length 262mm)
• Tool: D12R6 Hard ball end
• Tool path: Zig-zag contour processing
• Spindle speed: 8,000 rpm
• Feed rate: 2,000mm/min
• Total machining time: 1hr 58min

Mask Core Mold

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• Model: F series
• Material: S45C
• Size: 300 x 200 x 100 mm
• High speed and high accuracy mold machining
• High contour accuracy: 98.5% point error < 0.02mm, 85.8% point error < 0.012mm
• D12R6 ball end tool, 45° project zig-zag cutting
• Spindle speed: 10,000 rpm
• Feed rate: 4,000 mm/min

Benz Mold

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• Material: NAK 80 die steel
• 0.2G high acceleration mold machining
• High federate rough machining: D25, F10,000mm/min
• High speed surface finish machining: F4,000mm/min
• Surface roughness: Ra 0.4μm
• 45° project zig-zag cutting
• Spindle speed: 12,000 rpm
• Feed rate: 4,000 mm/min

Bumper Mold (Large)

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• Model: FA
• Material: FC300
• Size: 900 x 2300 x 930mm
• 5-axis synchronized machining, 30% efficiency improvement
• Long spindle nose for enhanced rigidity and reduced vibration
• D20R10 ball end tool, project zig-zag cutting
• Spindle speed: 8,000 rpm
• Feed rate: 5,000 mm/min

Automotive Sheet Metal Mold

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• Model: FA
• Material: FC300
• Size: 2300 x 1600 x 250mm
• 0.2G high acceleration mold machining
• High feedrate die surface finishing: F7,000mm/min
• High clear machining path
• Total finish time: 6.3hr
• D25 ball end tool, 45° project zig-zag cutting
• Spindle speed: 8,000 rpm
• Feed rate: 7,000 mm/min

Engine Hood Mold

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• Material: FC300
• Size: 2,000 x 1,600 x 500mm
• 10 m/min high speed machining
• 0.3G high acceleration machining
• Total finish time: 5.2 hrs.
• D25 ball end tool, pitch 0.5mm, surrounding isometric machining
• Spindle speed: 12,000rpm
• Feed rate: 5,000 mm/min

Mold Verification Workpiece

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• Model: GS/ SE
• Material: 2311
• Size: 150 x 60 x 30 mm
• D4R2 ball end tool finish
• Surround interpolation milling without tool mark
• Precise Z-reversed cutting with sharp edges and corners
• Surface roughness: Ra 0.8µm

Car Stamping Mold

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• Material: P20
• Size: L640mm x W505mm x H270mm
• Finish Tool: D16R8 Ball End, finish pitch 0.3mm
• Tool Path: 45° project zig-zag cutting
• High feed rate finishing: F3000→F5000
• High acceleration cutting: 0.05G→0.2G
• Total finishing time reduced by 20%: 6hr08min→4hr54min
• Surface roughness: Ra 0.6μm
• Spindle Speed: 15,000 rpm
• Feed rate: 5,000mm/min

Mold Base High Feedrate Machining

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• Model: SE / GS
• Material: S45C
• Size: 800 x 500 x 250mm
• Vc 220 m/min, 10 m/min high federate machining
• Boring positioning accuracy: 0.006 mm (Pitch 400x700mm)
• Spindle speed: 2,000rpm
• D40 R1 high feed tool

High Positioning Inspection Workpiece

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• Model: F Series/ BM/ XM/ XML/ XMF
• Material: FC30
• Size: 2,000 x 1,000 x 200mm
• 1.8x0.8 m high position accuracy of boring hole: 0.02mm
• D900 circular interpolation machining, circularity: 0.02mm
• 400x400mm squareness: 0.01mm

24m High Speed Machining Workpiece

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• Material: Al6061
• 24 m high speed machining, equal TEA tool path
• 70 mm long tool machining
• Tool: D25R1 end mill
• Spindle speed: 10,500rpm
• Feed rate: 24,000 mm/min

Ball Mold

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• Model: GS/ SE
• Material: 2311 Die steel
• Size: 300 x 200 x 150 mm
• D12R6 ball end tool, circular interpolation milling without tool mark
• Surface roughness: Ra 0.4µm

Deep Cavity Mold

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• Model: SM
• Material: P20 die steel
• Short-distance surround machining, high-precision feed control
• Four-quadrant commutation without chatter marks
• Simultaneous machining to maintain high finish, no over-cutting, no chatter marks
• Plane accuracy: -0.011 ~ 0.006mm
• Spherical accuracy: -0.012 ~ 0.006mm
• D20R1 end mill finishing
• Spindle speed: 3,500rpm
• Feed rate: 5,200mm/min

TIRE Mold (Segment Type)

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• Model: FA
• Material: S45C
• Size: 660 x 600 x 260mm
• Corner smooth flow cut via 5-axis synchronized machining
• D25 high feed rough cutting: F10,000
• F3,000 R6 finishing
• Multi-axis project machining
• Spindle speed: 15,000 rpm
• Feed rate: 4,000 mm/min

Ball Shape

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• Model: FA / GSF
• Material: Al6061
• Size: D280 mm
• 5 axis synchronized machining without deceleration
• High synchronized feedrate: F2,000
• High servo control, each axis feed > F10,000mm/min
• Finishing Time: <20min
• Surface accuracy: <±0.02mm

Tire Mold (Segment type)

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• Material: P20 Die Steel
• Size: L310 x W131 x H95mm
• One-step machining: High-feed rough machining, high-speed mold machining, and 5-axis synchronized machining corner flow cut
• High-feed rough machining: F7,200mm/min, Ap0.6mm
• High-speed mold machining: Ra<0.5μm
• 5-axis synchronized R0.5mm machining, effectively reducing tool length and avoiding interference.