BM Injection: Renovating equipment to improve production capacity (Part 2)

Since the inception of use Makino D200Z has shown that the investment of BM Injection is completely worth it.

Machining is now more convenient than ever with the D200Z’s custom memorization and input machining data. Accordingly, the operator only needs one activation operation instead of 2-3 as before (Including setting the milling command, selecting electrode and processing spark). Thanks to that, BM Injection company has saved a significant amount of operating costs because human resources are no longer required in terms of both quantity and quality, and at the same time, minimize downtime in the process. production process. In addition, the spindle load data is always updated on the management screen to help the operator forecast possible risks.

Speaking of accuracy, performing machining with an automatic chuck helps reposition the workpiece in the cycle with two rotating shafts for greater accuracy by eliminating tolerance build-up. The Makino machine has internal sensors and a strategic cooling spindle, ball screw and machine construction that allow for high precision keeping in the Whitchurch factory, even though it is not temperature controlled.

Director Tim Combes and his son Mark presented a 54 Rc Stavax prototype machined by Makino under controlled conditions at his lab in Japan with a total tolerance of 2µm and commented that the results were folded. Double can be achieved on the factory floor of BM Injection. “Size accuracy is very important when making molds”, says Mr.Tim Combes. We need to keep ± 0.012mm on cavity size, fill diameter and hole position.”

In the case of the use of auxiliary mold tools, it was previously necessary to grind them before machining the surface to achieve the required finishing. Now nothing needs grinding and the molds are finished in one setting on the D200Z. “Because the machine has high volumetric accuracy, which results in less manual polishing, it is easier to keep the true shape of the mold because less material is removed”, said Mr.Mark Combes. This is especially important when making tools for making lenses and other optical products.”

In addition to the Makino machine that is capable of keeping very high accuracy across its entire 350 x 300 x 250mm working volume, another reason for its choice is its small frame of around 2.75 x 3.75m, which This is very important because space is limited within the Whitchurch facility. Other features of the machine include the B-axis with 180 ° inclination at 100 rpm, the C-table 150 rpm, the HSK-E50 rotation shaft 30,000 rpm, and the cutting speed up to 60 m/min.

The last step in the BM Injection process is the surface finish. In the past, a mold took 20 hours to polish by hand. However, with the existing electric spark processing equipment, neat milling lines have helped the company reduce this time to only 3-4 hours. Waiting time from ordering to completion has been cut by 40% on average. This is an incredible step forward in productivity at BM Injection.

Productivity and Quality Office