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Material

Machining Case Study

Applications

Connector Mold Electrode

Size:

167×42×10mm

Materials:

Copper

Machine:

JDHGT400T

Highlights:

+ Machining with D0.3mm and R0.15mm tools;

+ The tolerance deviation of 2000 small columns is within ± 5μm, and the dimensional consistency is 5μm;

+ The distance deviation between two adjacent small columns is within ± 2μm;

+ The burrs are less than 3μm.

Connector Mold Electrode

Size:

70×70×25mm

Materials:

Copper

Machine:

JDHGT400T

Highlights:

+ Using D0.3mm small tool for processing;

+ The tolerance deviation of 200 small columns is within ± 5μm, and the dimensional consistency is 5μm;

+ The distance deviation between two adjacent small columns is within ± 2μm;

+ The burrs are less than 3μm.

Gear Mold Electrode

Size:

47×47×15mm

Materials:

Copper

Machine:

JDHGT400T

Highlights:

+ Machining with R0.2mm tool;

+ The tolerance deviation of 34 tooth surfaces is within ± 5μm;

+ The tooth surfaces don’t have any witness mark.

Connector Mold Electrode

Size:

167×42×10mm

Materials:

Copper

Machine:

JDHGT400T

Highlights:

+ Machining with D0.3mm and R0.15mm tools;

+ The tolerance deviation of 2000 small columns is within ± 5μm, and the dimensional consistency is 5μm;

+ The distance deviation between two adjacent small columns is within ± 2μm;

+ The burrs are less than 3μm.

Connector Mold Electrode

Size:

70×70×25mm

Materials:

Copper

Machine:

JDHGT400T

Highlights:

+ Using D0.3mm small tool for processing;

+ The tolerance deviation of 200 small columns is within ± 5μm, and the dimensional consistency is 5μm;

+ The distance deviation between two adjacent small columns is within ± 2μm;

+ The burrs are less than 3μm.

Gear Mold Electrode

Size:

47×47×15mm

Materials:

Copper

Machine:

JDHGT400T

Highlights:

+ Machining with R0.2mm tool;

+ The tolerance deviation of 34 tooth surfaces is within ± 5μm;

+ The tooth surfaces don’t have any witness mark.

Camera Mold Electrode

Size:

22×22×3.5mm

Materials:

Copper

Machine:

JDHGT400T

Highlights:

+ R0.5mm tool is used in finishing;

+ The tolerance deviation of 9 grooves is within ± 5μm and the dimensional consistency is 5μm;

+ Surface roughness Ra < 100nm, no tool marks can be seen after magnified 30 times.

Needle Column Electrode

Size:

44×24×10mm

Materials:

Copper

Machine:

JDHGT400T

Highlights:

+ 4 small columns, the minimum diameter is 0.2mm, and the height is 14mm;

+ The tolerance deviation of each column is within ± 5μm and the dimensional consistency is 5μm;

+ Surface roughness Ra < 150nm.

Six-Position Earphone Mold Test Piece

Size:

75×75×30mm

Materials:

STAVAX( HRC52 )

Machine:

JDGR200T

Highlights:

+ R1mm PCD tool continuous polishing for more than 19h;

+ The remaining stock range of all positions is 0.01 mm;

+ Single position roughness Sa ≤ 20 nm.

Connector Mold Electrode

Size:

167×42×10mm

Materials:

Copper

Machine:

JDHGT400T

Highlights:

+ Machining with D0.3mm and R0.15mm tools;

+ The tolerance deviation of 2000 small columns is within ± 5μm, and the dimensional consistency is 5μm;

+ The distance deviation between two adjacent small columns is within ± 2μm;

+ The burrs are less than 3μm.

Connector Mold Electrode

Size:

70×70×25mm

Materials:

Copper

Machine:

JDHGT400T

Highlights:

+ Using D0.3mm small tool for processing;

+ The tolerance deviation of 200 small columns is within ± 5μm, and the dimensional consistency is 5μm;

+ The distance deviation between two adjacent small columns is within ± 2μm;

+ The burrs are less than 3μm.

Gear Mold Electrode

Size:

47×47×15mm

Materials:

Copper

Machine:

JDHGT400T

Highlights:

+ Machining with R0.2mm tool;

+ The tolerance deviation of 34 tooth surfaces is within ± 5μm;

+ The tooth surfaces don’t have any witness mark.

Camera Mold Electrode

Size:

22×22×3.5mm

Materials:

Copper

Machine:

JDHGT400T

Highlights:

+ R0.5mm tool is used in finishing;

+ The tolerance deviation of 9 grooves is within ± 5μm and the dimensional consistency is 5μm;

+ Surface roughness Ra < 100nm, no tool marks can be seen after magnified 30 times.

Needle Column Electrode

Size:

44×24×10mm

Materials:

Copper

Machine:

JDHGT400T

Highlights:

+ 4 small columns, the minimum diameter is 0.2mm, and the height is 14mm;

+ The tolerance deviation of each column is within ± 5μm and the dimensional consistency is 5μm;

+ Surface roughness Ra < 150nm.

Six-Position Earphone Mold Test Piece

Size:

75×75×30mm

Materials:

STAVAX( HRC52 )

Machine:

JDGR200T

Highlights:

+ R1mm PCD tool continuous polishing for more than 19h;

+ The remaining stock range of all positions is 0.01 mm;

+ Single position roughness Sa ≤ 20 nm.

Small Precision Plastic Mold Insert

Size:

30.000×51.865×47.020mm

Materials:

S136(HRC52)

Machine:

JDGR100

Highlights:

+ Multi-face machining, the shape error accuracy is micron level;

+ The minimum circular angle of right side wall is R0.3mm;

+ Small tool milling replaces EDM.

Mold Inserts for Automobile Braking Four Loop Shell

Size:

141×131×197mm

Materials:

H13(HRC52)

Machine:

JDGR400T

Highlights:

+ Surface dimensional accuracy within ±10μm;

+ The surface tool mark has good consistency, and the surface roughness Ra ≤ 0.2μm.

Automobile Lamp Mold Part

Size:

75×100×96mm

Materials:

H136(HRC30)

Machine:

JDGR400T

Highlights:

+ Surface dimensional accuracy is ±10μm;

+ The surface tool mark has good consistency, and the surface roughness Ra ≤ 0.3μm.

Connector Mold Electrode

Size:

167×42×10mm

Materials:

Copper

Machine:

JDHGT400T

Highlights:

+ Machining with D0.3mm and R0.15mm tools;

+ The tolerance deviation of 2000 small columns is within ± 5μm, and the dimensional consistency is 5μm;

+ The distance deviation between two adjacent small columns is within ± 2μm;

+ The burrs are less than 3μm.

Connector Mold Electrode

Size:

70×70×25mm

Materials:

Copper

Machine:

JDHGT400T

Highlights:

+ Using D0.3mm small tool for processing;

+ The tolerance deviation of 200 small columns is within ± 5μm, and the dimensional consistency is 5μm;

+ The distance deviation between two adjacent small columns is within ± 2μm;

+ The burrs are less than 3μm.

Gear Mold Electrode

Size:

47×47×15mm

Materials:

Copper

Machine:

JDHGT400T

Highlights:

+ Machining with R0.2mm tool;

+ The tolerance deviation of 34 tooth surfaces is within ± 5μm;

+ The tooth surfaces don’t have any witness mark.

Camera Mold Electrode

Size:

22×22×3.5mm

Materials:

Copper

Machine:

JDHGT400T

Highlights:

+ R0.5mm tool is used in finishing;

+ The tolerance deviation of 9 grooves is within ± 5μm and the dimensional consistency is 5μm;

+ Surface roughness Ra < 100nm, no tool marks can be seen after magnified 30 times.

Needle Column Electrode

Size:

44×24×10mm

Materials:

Copper

Machine:

JDHGT400T

Highlights:

+ 4 small columns, the minimum diameter is 0.2mm, and the height is 14mm;

+ The tolerance deviation of each column is within ± 5μm and the dimensional consistency is 5μm;

+ Surface roughness Ra < 150nm.

Six-Position Earphone Mold Test Piece

Size:

75×75×30mm

Materials:

STAVAX( HRC52 )

Machine:

JDGR200T

Highlights:

+ R1mm PCD tool continuous polishing for more than 19h;

+ The remaining stock range of all positions is 0.01 mm;

+ Single position roughness Sa ≤ 20 nm.

Small Precision Plastic Mold Insert

Size:

30.000×51.865×47.020mm

Materials:

S136(HRC52)

Machine:

JDGR100

Highlights:

+ Multi-face machining, the shape error accuracy is micron level;

+ The minimum circular angle of right side wall is R0.3mm;

+ Small tool milling replaces EDM.

Mold Inserts for Automobile Braking Four Loop Shell

Size:

141×131×197mm

Materials:

H13(HRC52)

Machine:

JDGR400T

Highlights:

+ Surface dimensional accuracy within ±10μm;

+ The surface tool mark has good consistency, and the surface roughness Ra ≤ 0.2μm.

Automobile Lamp Mold Part

Size:

75×100×96mm

Materials:

H136(HRC30)

Machine:

JDGR400T

Highlights:

+ Surface dimensional accuracy is ±10μm;

+ The surface tool mark has good consistency, and the surface roughness Ra ≤ 0.3μm.

Automobile Door Mold Insert

Size:

250×200×172mm

Materials:

H13(HRC52)

Machine:

JDCT600T+JDGR400T

Highlights:

+ Using tools: D21R0.8, D6R3, D4R2, D2R1, etc.;

+ The workpiece position alignment is completed within 1 minute by using JINGDIAO on-machine inspection system;

+ The surface witness mark is less than 5μm.

Automobile Engine Cylinder Mold Insert

Size:

183×184×191mm/div>

Materials:

H13(HRC52)

Machine:

JDCT600T+JDGR400T

Highlights:

+ Using tools: D21R0.8, D6R3, D3R1.5, D1.5R0.75;

+ The range of remaining stock is 15μm;

+ The surface texture is uniform, and the surface roughness Ra < 0.2μm;

+ The surface witness mark is less than 5μm.

Automobile Door Mold Insert

Size:

115×89×125mm

Materials:

S136(HRC30)

Machine:

JDCT600T+JDGR400T

Highlights:

+ Using tools: D21R0.8, D8R0.5, D6R0.5, D1R0.5, etc.;

+ The surface roughness Ra0.12-0.3μm;

+ The surface witness mark is less than 5μm.

Applications

Fresnel Lens Mold Part Test Piece

Size:

Φ30×60mm

Material:

S136(HRC50)

Machine:

JDGR200T

Highlights:

＋ Finishing steadily for 99h with a PCD tool(R0.1mm), and the cutting depth is 2 μm, tool wear is less than 1μm;

＋ Surface roughness: Sa<0.05μm;

＋ Dimensional accuracy: ±5μm.

Automotive Light Guide Mold Part Test Piece

Size:

580×70×150mm

Material:

STAVAX(HRC52)

Machine:

JDHGT600T

Highlights:

＋ Finishing steadily for 150h with a PCD tool(R0.1mm);

＋ Surface roughness: Sa<0.05μm.

HUD Mirror Mold Part Test Piece

Size:

300×200×50mm

Material:

M333(HRC50)

Machine:

JDGR300H

Highlights:

＋ Finishing steadily for 82h with a PCD tool (R4mm);

＋ Surface roughness: Sa<10nm, Sv<35nm，surface waviness is less than 25nm.

Applications

The Fitting Testpiece of Hole and Column

Size:

200×200×200mm(single plate)

Material:

S136(HRC52)

Machine:

JDHGT600T

Highlights:

＋ Milling and grinding of the inner holes;

＋ Surface roughness of holes is Ra ＜ 0.1μm;

＋ Position deviation of holes is less than 3μm;

＋ Holes and columns in the same diameter can be interchangeably fit.

Upper Cover Plate Part of the Metering Pump

Size:

φ45×15mm

Material:

440C(HRC55-60)

Machine:

JDHGT600T

Highlights:

＋ Based on the center hole, the dimensional error, positioning error and cylindricity of the positioning holes are all less than 5μm;

＋ Surface roughness Ra＜0.2μm.

Mold Base

Size:

400×310×35mm

Material:

4Cr13(HRC52)

Machine:

JDHGT600T

Highlights:

＋ Consistency error of holes ≤2μm; Dimensional accuracy of hole diameter ＜ 3μm;

＋ Positional accuracy of holes is ±5μm; Roundness, cylindricity, verticality ≤ 3μm.

五轴 CNC加工实例

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Mail：ken.wang@kunlun-material.com

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