In the mid-1990s, high-speed milling began to revolutionize the mold-making industry, particularly through the integration of hard machining techniques. This innovation marked a significant shift in manufacturing processes, enabling more efficient and precise production. By employing high-speed hard milling, molds can be processed under a single clamping condition, which not only reduces processing time but also improves surface quality and accuracy. It streamlines the workflow, shortens the overall manufacturing cycle, and lowers production costs. High-speed hard milling has largely eliminated the need for electrode making, EDM (Electrical Discharge Machining), and polishing in many cases. By the late 1990s, it had replaced EDM in numerous applications, except for narrow slots, deep grooves, and very small internal corners. In recent years, with the development of fine milling cutters—some as small as 0.03mm to 0.1mm in diameter—and the adoption of micro-milling technology, even those challenging areas have become processable using small-diameter end mills. As a result, the reliance on EDM has further decreased. According to a 2004 study by the Fraunhofer Institute of Production Technology in Germany, high-speed hard milling is expected to increase its share in tooling and mold-making by 20% in the following years, while EDM will decline by 12%. This trend highlights the growing popularity of high-speed hard milling, which has now become a key process in mold manufacturing. Despite the benefits, successful implementation of this technology requires certain conditions. Companies must have skilled professionals who understand the process, along with suitable high-speed machining equipment and appropriate tooling. The choice of tools, cutting parameters, and cooling methods all play a critical role in determining efficiency, quality, and cost. For example, a Chinese toy factory used a German Hermle C800V vertical machining center with nine different types of end mills and ball end mills. They applied high-flow cooling lubrication, reducing processing time to 125 minutes. However, after milling, they still needed to perform EDM for the cavity bottom. Through a Sino-German research project, the Darmstadt Institute of Technology optimized the process by replacing EDM with high-speed finishing milling. The results showed that the number of tools was reduced from 9 to 6, cutting time dropped by 26%, and surface roughness improved significantly. Machine tools used for high-speed hard milling must have high spindle speeds, power, rigidity, and dynamic performance. Modern machines often operate at 40,000 to 60,000 rpm, supporting small-diameter cutters. However, for ultra-fine cutters (0.2–1 mm), higher spindle speeds are necessary. Axial acceleration is also important, with current values reaching up to 3 g, and future expectations rising to 5 g. Five-axis machines are especially beneficial for complex surfaces, allowing better tool access and reducing vibration and tool breakage risks. Cutting tools, such as solid carbide end mills with TiAlN coatings, are essential for hard milling. These tools can handle materials up to 65 HRC, with cutting speeds reaching 200–350 m/min. Tool holders, like HSK-type shrink-fit systems, ensure minimal runout and high rigidity, crucial for maintaining precision during high-speed operations. Cooling is generally avoided in high-speed hard milling due to thermal shock risks. Instead, compressed air or cold air is used to remove chips and cool the tool, improving tool life by up to 30%. This approach avoids damage caused by sudden temperature changes and enhances surface finish. To maximize the benefits of high-speed hard milling, several principles should be followed: keep tool overhang as short as possible, use climb milling to extend tool life, minimize tool runout, avoid wet machining, select appropriate cutting parameters, and optimize roughing to leave only a thin layer for finishing. Overall, high-speed hard milling has proven to be a game-changer in mold manufacturing, offering faster processing, better quality, and lower costs. As technology continues to evolve, its role in the industry will only grow.

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