Moldstar 90 is a high-performance copper mold alloy that has become increasingly popular in the manufacturing industry due to its excellent thermal conductivity, wear resistance, and machinability. This unique alloy offers significant advantages over traditional mold materials, such as steel, making it a top choice for many applications. In this comprehensive guide, we will explore the best practices and techniques for machining Moldstar 90 copper mold alloy to ensure optimal performance and longevity.
Introduction to Moldstar 90 Copper Mold Alloy
Moldstar 90 is a proprietary copper alloy developed by Performance Alloys & Services Inc. It consists of a blend of copper, chromium, and zirconium, which provides it with exceptional hardness, strength, and thermal conductivity. These characteristics make it an ideal material for manufacturing plastic injection molds, blow molds, and die-casting tools.
One of the primary reasons Moldstar 90 has gained popularity is its ability to reduce cycle times in molding operations. Its high thermal conductivity allows for rapid cooling of the molded part, which translates to increased production efficiency and reduced energy consumption.
Machining Guidelines for Moldstar 90
Moldstar 90 can be machined using conventional machining methods, such as milling, turning, drilling, and grinding. However, due to its unique properties, certain considerations must be taken into account to achieve the best results. Below are some general guidelines for machining Moldstar 90:
Cutting Tools
Selecting the appropriate cutting tools is crucial for achieving optimal machining results. Carbide tools are recommended for machining Moldstar 90 due to their ability to withstand the high cutting forces and temperatures generated during the process. High-speed steel (HSS) tools can also be used, but they may not provide the same level of performance and tool life as carbide tools.
Cutting Speeds and Feeds
Moldstar 90 can be machined at relatively high cutting speeds, which can help reduce machining time and improve productivity. However, it is essential to ensure that the cutting speeds and feeds are within the recommended range to avoid excessive tool wear and potential damage to the workpiece. The following are some general guidelines for cutting speeds and feeds when machining Moldstar 90:
Milling: Cutting speed of 300-500 SFM (surface feet per minute) and feed rate of 0.002-0.006 IPT (inches per tooth)
Turning: Cutting speed of 400-600 SFM and feed rate of 0.008-0.015 IPR (inches per revolution)
Drilling: Cutting speed of 100-200 SFM and feed rate of 0.002-0.006 IPM (inches per minute)
It is always a good idea to start with conservative cutting speeds and feeds and gradually increase them based on tool performance and workpiece quality.
Coolants and Lubricants
The use of appropriate coolants and lubricants is essential for efficient machining of Moldstar 90. They help dissipate heat, reduce friction, and prevent tool wear. Water-soluble coolants are recommended for most machining operations, as they provide excellent cooling and lubrication properties. For operations that require minimal coolant, such as drilling and tapping, a high-quality cutting oil can be used.
Tool Path Strategies
Choosing the right tool path strategy can significantly impact the machining efficiency and workpiece quality. When machining Moldstar 90, it is essential to minimize the number of tool changes and reduce the amount of time the tool spends in the cut. This can be achieved by using strategies such as:
Adaptive clearing: This is a high-efficiency roughing strategy that maintains a constant tool load, reducing tool wear and improving productivity.
Trochoidal milling: This technique involves using a constant circular tool path, which reduces tool engagement and heat generation, resulting in longer tool life and improved workpiece quality.
Conclusion
Machining Moldstar 90 copper mold alloy can be a straightforward and efficient process when the proper techniques and guidelines are followed. By selecting the appropriate cutting tools, optimizing cutting speeds and feeds, using suitable coolants and lubricants, and employing effective tool path strategies, manufacturers can achieve excellent results while reducing cycle times and improving productivity. With its numerous benefits and growing popularity, Moldstar 90 is poised to become a staple material in the mold-making industry, and understanding how to machine it effectively is essential for success.
