Injection Mould Door Handle

1
Characteristics of the Workpiece Material

Material: 1.2330
Hardness: 34 HRC
DIN: 35 CrMo 4
Composition: 0.35%C, 1%Cr, <1%Mo
Description: cold work steel, low alloy
Tensile strength: <1000 N/mm2

The hardness of this material is not very high, which will result
in a insignificant resistance against a cutting process. Due to
the low contents of Chrome and Molybdaen and therelatively
low tensile strength, a machining process without major
problems can be expected.

2
Objectives of the Test Cut

Objectives
Evaluate performance and
accuracy of machining center

Target Priority Goal

Value
Surface 0.6
Finish Ra 1 [Ra]
Accuracy 10
2 [m]
Machining
Time 3 [min]

3
Test Cut Results: Machining Sequence

Number of Teeth

Processing Time
Spindle Speed
Corner-Radius

Cutting Depth
Diameter

Stepover
Feedrate
D R z n vf ae ap t
-1
Manufacturing Step Cutting Tool [mm] [mm] - [min ] [mm/min] [mm] [mm] [min]
roughing milling head 50 0.4 5 1000 750 20 3 75
roughing HXR endmill 12 3 4 3000 900 4.8 2.5 95
roughing deep cavity torus endmill 10 2.5 4 2100 600 1.5 0.25 188
roughing HX endmill 10 - 4 4800 2000 4 2 2
prefinishing ball nose 12 6 2 20000 4500 0.5 0.3 34
prefinishing deep
ball nose 12 6 2 15000 3000 0.005* 0.3 28
cavity
prefinishing pockets ball nose 6 3 2 20000 4500 0.005* 0.2 42
* stepover is defined by Rt Processing Time 464

4
Test Cut Results: Machining Sequence

Number of Teeth

Processing Time
Spindle Speed
Corner-Radius

Cutting Depth
Diameter

Stepover
Feedrate
D R z n vf ae ap t
-1
Manufacturing Step Cutting Tool [mm] [mm] - [min ] [mm/min] [mm] [mm] [min]
finishing endmill 16 - 9 3000 480 6.4 3 28
finishing short ball nose 10 5 2 20`000 2800 0.005* 0.04 152
finishing deep cavity ball nose 10 5 2 20`000 2800 0.005* 0.04 294
finishing pockets ball nose 6 3 2 20`000 2400 0.005* 0.05 82
finishing radius ball nose 3 1.5 2 20`000 2000 0.005* 0.05 135
finishing radius ball nose 2 1 2 20`000 1600 0.04 0.04 25
finishing deep slots endmill 11 - 4 5300 800 - 2 12
* stepover is defined by Rt Processing Time 728

5
Test Cut Results: Machining Sequence

Number of Teeth

Processing Time
Spindle Speed
Corner-Radius

Cutting Depth
Diameter

Stepover
Feedrate
D R z n vf ae ap t
-1
Manufacturing Step Cutting Tool [mm] [mm] - [min ] [mm/min] [mm] [mm] [min]
milling slots ball nose 0.8 0.4 2 20`000 400 0.08 0.02 172
centre drilling 90 drill 6 - 2 3000 500 - 2.1 2
drilling drill 3.3 - 2 1900 300 - 15 6
tapping tap M4 - 3 400 - - 14 4
centre drilling 90 drill 12 - 2 3000 500 - 5.2 2
drilling drill 10 - 2 780 100 - 25 12
drilling drill 10 - 2 780 80 - 130 51
Processing Time 249
Total Processing Time 1441

6
Test Cut Results: Pictures