Basic study to reduce polishing process in mold manufacturing - Relationship between the surface pattern after machining and the polishing property -

This research examines the method to reduce the polishing work of a large press die by completing the cutting process with one ball endmill and not causing joints by tool change. The cutting distance is determined by tool life, so there is a limit to the finished surface roughness. Therefore, even if the surface roughness is not small, it is possible to reduce the polishing work by processing the cutting surface to pattern that is easy to polish. Namely, this research will investigate the cutting process considering the polishing work which is the next process. This research reduces the manufacturing cost of large press dies and contributes to strengthening the competitiveness of Japanese mold manufacturing. As a result, the polishability changes depending on the pattern of the finished surface after machining. The polishing efficiency becomes higher when polishing from the vertical direction to the mountains of the concave-convex pattern. Further, it was clarified that polishing efficiency is improved without depending on the polishing direction by cutting the finishing surface of ball endmill into a cross pattern. In other words, it was found that the polishing work can be simplified by cutting the surface pattern in consideration of polishing easiness in addition to reducing the surface roughness in cutting process.