Case Study: SDF End Mills for Pre-Polishing Tool Forming in Mold Manufacturing

Industry Background and Machining Challenges:

Mold manufacturing is a vital segment of the precision engineering industry, especially for producing high-quality components in automotive, consumer electronics, and medical sectors. Pre-polishing tool forming is a critical stage in the mold production process, where the tooling surfaces must be prepared with high precision to ensure optimal polishing results. The primary products include cavity molds, core molds, and insert molds, which are often made from hardened steels (e.g., H13, P20, S136) and require tight dimensional tolerances and excellent surface finish before final polishing.

Typical processing flows include rough milling, semi-finishing, finishing, and slotting operations. The challenges in this stage include:

• Material hardness: Common workpiece materials like hardened tool steel (up to HRC 45–60) demand high-performance cutting tools to avoid premature tool wear.
• Surface finish requirements: A Ra value of less than 0.8 μm is frequently required before polishing, necessitating superior tool stability and edge sharpness.
• Efficiency bottlenecks: High production volumes and complex geometries create pressure to reduce machining time and improve tool life.
• Chip control: Proper chip formation and evacuation are essential to prevent tool damage and maintain part quality.

Technical Requirements for End Mills in This Industry:

In mirror mold pre-finishing applications, the following core performance requirements are critical:

• High metal removal rate: Ensures faster cycle times without compromising tool integrity.
• High wall perpendicularity and corner accuracy: Maintains mold shape and dimensional consistency.
• High slotting performance: Achieves smooth and clean internal features for polishing readiness.
• Excellent wear resistance: Prolongs tool life under high-pressure and high-temperature conditions.
• Effective chip breaking: Reduces the risk of tool damage and improves machining consistency.
• Thermal stability: Maintains tool performance in prolonged cutting operations.
• Chip-to-edge clearance: Minimizes flank wear and extends tool life.
• Impact resistance and edge toughness: Reduces chipping and edge failure in interrupted cuts or heavy loads.

SDF’s Product Solution:

SDF’s reamable end mills are specifically engineered for pre-polishing mold forming in hardened materials. These tools combine advanced design features, coating technologies, and high-grade carbide substrates to deliver exceptional performance in critical machining environments.

Structural Design:

• Optimized flute geometry with high helix angles to improve chip evacuation and surface finish.
• Ultra-precise core design to maintain high rigidity and reduce deflection in deep cavity milling.
• Enhanced cutting edge preparation (e.g., TICN + DLC) to improve edge sharpness and durability.
• Interchangeable indexable inserts with precise clamping mechanisms for fast tool change and long tool life.

Coating Technology:

• Multi-layer PVD coatings that offer excellent oxidation resistance and wear protection.
• High-temperature stability up to 900°C to sustain performance in high-speed and high-feed applications.
• Low friction coefficient to reduce heat generation and tool wear.

Material Selection:

• High-purity carbide substrates with fine grain structure for enhanced toughness and thermal resistance.
• Customized grade development for specific workpiece materials and cutting conditions.

Typical Customer Application Case:

A European customer specializing in high-precision plastic injection molds faced significant challenges during pre-polishing forming operations. The workpieces were made from H13 tool steel with a hardness of HRC 48–52, and the customer required a stable tooling solution that could maintain high accuracy while reducing tooling costs and increasing productivity.

Challenges included:

• Poor chip control during slotting operations led to tool failure and rework.
• Short insert life due to high temperature and pressure in deep cavity milling.
• Inconsistent surface finish across mold cavities.

SDF’s technical team conducted a full process audit and provided a tailored tooling solution, including:

• Recommending a high-helix, 4-flute indexable end mill with a dedicated grade for H13 steel.
• Customizing the PVD coating to enhance heat resistance and edge stability.
• Providing in-situ cutting tests and real-time performance monitoring.

Conclusion and Brand Value Summary:

SDF has demonstrated strong technical capabilities and a deep understanding of the mold manufacturing industry’s unique requirements. By integrating advanced indexable end mill designs, high-performance coatings, and precision carbide grades, SDF products are able to deliver superior results in mirror mold pre-finishing processes. The SDF solution not only matches but often exceeds the performance of foreign competitors, offering a cost-effective and reliable alternative for global mold makers.

As the demand for higher precision and faster cycle times increases in mold manufacturing, SDF continues to invest in R&D and localized support to meet the evolving needs of its customers. The company is positioned as a strategic partner for mold shops seeking high-performance cutting tools that provide consistent quality, extended tool life, and improved process efficiency. With the continued refinement of its indexable end mill technology, SDF is well-placed to lead in the future of mold pre-polishing tooling solutions.