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Standardisation Of Mould Bases

Standardisation of Mould Bases

There are plenty of potential benefits in making good use of standardisation concepts when sourcing a mould base. Article by Lung Kee Group (LKM).

Injection moulding is one of the key processes in today’s manufacturing industry, enabling manufacturers to achieve economy of scale in production of high-volume plastic or metal parts. The quality of the mould, usually defined by its precision and overall reliability, plays a critical role in determining the success of the final product.

Basic Structure

In very simple terms, a mould base is a semi-finished mould. The basic structure of a mould base consists of several drilled or machined mould plates assembled together with mould components. Modern mould makers tend to purchase mould bases from specialist mould base suppliers, in order to reduce overall manufacturing time and the costs associated with machinery and raw material investments. Perhaps most importantly, using a mould base enables the mould maker to focus on the high value-adding portions of the mould manufacturing process, such as design, polishing and final production tests.

Just like many industrial processes, there are plenty of potential benefits in making good use of standardisation concepts when sourcing a mould base. The most obvious one is cost, as standard mould bases can be ordered from catalogue, offering good price transparency. The leading suppliers in Japan, Europe and Asia all have highly engineered production lines to achieve a high level of machining precision on a consistent basis—so, by making use of their standard products, mould makers can also enjoy the economy of scale in terms of competitive pricing. Standardisation also helps mould makers’ internal workflow by speeding up the design process. In fact, many CAD packages contain libraries of common mould base standards.

Defining Qualities

A good standard mould base has three defining qualities: reliable material, reliable precision, and reliable availability. The importance of raw materials should not be underestimated, as moulds made with poor materials risk plate deformation or even fracture due to metal fatigue. Reliable precision is quite often easier said than done, as the quality from small scale manufacturer tends to highly depend on individual workmanship.

And of course, good quality products mean nothing if one cannot buy them easily. Leading mould base suppliers tend to have superior financial strength to invest in good material procurement capabilities, strong CNC machine portfolio and large inventory, and above all, they tend to have a commitment to high quality.

LKM Discusses Benefits of Standard Mould Bases for Vietnam Manufacturers

Established in 1975, Lung Kee Group (LKM) is one of the leading mould base manufacturers worldwide. The company is headquartered in Hong Kong, with product lines ranging from standard and custom-made mould bases, to precision machining and mould components. LKM is also a distributor of quality tool steel brands such as Japanese Daido, Assab Uddeholm, Arcelormittal, Bao Steel, and its own brand ‘LKM Special Steel’.

For the past 40 years, LKM is instrumental in the growth of the mould making industry in Asia. Through commitments to quality and integrity, and a relentless drive to excellence, LKM has developed from its modest beginning into an industry leading powerhouse in mould base manufacturing. In fact, LKM was the first Hong Kong company to introduce CNC machining centres for mould base manufacturing. LKM’s reputation as an industry leader in the mould base industry was further solidified through its listing on the Hong Kong Stock Exchange in 1993.

At present, LKM manufactures over 55,000 complete sets of mould bases per month. In term of custom-made mould base, the company has world-class machining capacity, powered by a team of engineers and machine operators with over 30 years of combined experience in making complex custom-made mould base for the automotive industry and precision machinery.

In an interview with Asia Pacific Metalworking Equipment News (APMEN), Cyrus Lau, assistant manager of Lung Kee Metal Japan Co. Ltd (HCMC Office)—LKM’s Vietnam office—talks about Vietnam’s mould & die industry and what’s driving growth in the market.

Q: How would you describe Vietnam’s mould and die industry?

Cyrus Lau: Vietnam is one of the biggest centres of manufacturing industry in Southeast Asia. Its mould & die market is comprehensive, ranging from sheet metal dies, die casting dies, and forging dies, to jigs, fixtures, gauges, and more. Key factors driving the market include the growing support from Japanese moulding companies. Overall, there is a large number of local manufacturers, suppliers, and distributors operating in Vietnam’s mould and die industry.

Q: How does LKM position itself in the Vietnam mould & die market?

CL: We are a mould base manufacturer and machinery specialist. We don’t think any company in our industry can claim to produce over 100 tonnes of metal chips like we do! But most importantly, our LKM standard is known to be very reliable, and is one of the most popular mould base brand in the world. When customers buy LKM, they know they get good and reliable quality. We have a large number of Japan-made machining centres, and we can cut over 100 tons of steel materials a day. In addition, we work with customers and provide them with materials and processing advice.

Q: How are you helping your customers address their manufacturing challenges?

CL: For Vietnamese mould makers, reliable quality and speed are very important—and the easiest way to improve this is by adopting standardisation in mould bases. This will improve lead time, quality, and make mould designs easier. Of course, standard products also tend to be cost efficient, which is clearly beneficial for mould makers.

 

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Agathon Showcases Its Innovations For Tool And Mould In EMO 2019

Agathon Showcases Its Innovations For Tool And Mould In EMO 2019

At the EMO 2019 Agathon will highlight new developments in the field of machinery and services, as well as solutions and innovations for guiding, centering and quick-change, especially for tool and mould making.

Agathon will be presenting its broad portfolio for tool and machine construction to visitors at the EMO 2019. The company highlights their top products such as the roller guide systems, in particular, for tool and mould making, but also for mechanical engineering and automation.

This porfolio also includes the Mini Fine Centering, which has gained an excellent reputation since its market introduction in the spring of 2018. With the static application of the Mini Fine Centering tool and mould inserts can be backlash-free, easy rolling and thus highly precise centered and they can also be changed extremely fast, without expert knowledge and without tilting.

Mechanical engineers are increasingly enjoying the opportunities for quick change, which is offered by the mini-fine centering. A popular field of application is the quick exchange of clamping tools. Other areas of application for the Mini Fine Centering include precision automation, for example, when gripper tools are positioned. There, the Mini Fine Centering ensures maximum process reliability, it eliminates vibrations and guarantees gentle and precise part removal.

The Mini Fine Centering can now also be used for dynamic applications. In particular, the centering of floating cavities in multi-cavity tools and moulds should offer a broad field of application for the Mini Fine Centering. Thanks to its small footprint, the number of cavities can be increased by up to 30 percent. Since the Mini Fine Centering is not paired, additional bushings of the standard 7989 can be used – in particular for turning tools or automation solutions, this offers new application possibilities.

Furthermore, the new maintenance-free sliding bushing is Agathon’s third spring innovation. It distinguishes itself especially for dry running, whereby the small backlash enables a very precise guidance. The sliding surface of the bushing is designed and structured to achieve a very high performance together with the surface of the pillars, the counter partner from the Agathon range.

 

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Tungaloy Boosts Deep Hole Drilling Productivity

Tungaloy Boosts Deep Hole Drilling Productivity

Tungaloy has expanded its DeepTriDrill line of indexable gun drills to include new drill diameters ranging from ø12mm to ø13.5mm. With new drill sizes in the lineup, DeepTriDrill can now address the diverse deep hole drilling needs of automotive and mould set parts for maximum efficiency and stability.

In addition, the drill diameter can easily be altered in increments of 0.01mm to the required hole sizes simply by placing dedicated adjusting shims beneath the guide pads, allowing an overall reduction of cycle time and manufacturing costs in diverse deep drilling applications. The H-class insert features unique cutting edge configuration that provides hole accuracy at greater feed rates, while also ensuring smooth chip evacuation.

The expanded line includes 12 drill bodies and one insert.

 

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