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The Mikron HSM 500 MoldMaster from GF Machining Solutions is intended for a range of mold and die-related applications, such as production of steel mold cores, hot pressing dies and sinker-EDM electrodes. The high-speed milling machine is equipped with a 42,000-rpm HSK spindle that uses ceramic hybrid ball bearings and oil-air lubrication, as well as a liquid-cooled jacket and bearings. The vector-controlled motor spindle is said to provide fast acceleration to full speed as well as high torque at low speeds. Feed rates range to 784.4 ipm (20 m/min.), and rapid traverse rates range to 1,574.8 ipm (42 m/min.). The machine’s absolute optical linear scales with 20-nanometer step resolution on the X, Y and Z axes enable precise machine positioning.

According to GF Machining Solutions, the machine’s polymer granite base material and liquid-cooled motors help to minimize thermal effects on accuracy. The cross-slides are weight-optimized for dynamic machine motion. The machine’s portal construction and pyramid-shaped design provide stability and rigidity within a compact footprint. Its axes are fully covered, and a hood protects the machine. An automatic central lubrication system ensures that linear guides and ballscrews are lubricated without removing any protective covering. Two suction units and separate dust bins enable fast evacuation of graphite dust.

The milling machine also is equipped with SmartMachine functions, including vibration monitoring, reduced machine warm-up wait time and optimized machine motion for increased tool life, improved productivity and shorter cycle times. The “advanced process system” displays vibrations occurring during the milling process as a G load, enabling users to intervene and adjust for optimized cutting conditions and surface finish, while the “intelligent thermal control” function actively compensates for thermal displacement in the cutting tool’s center line. The “operator support system” enables users to access the internal parameters of the CNC and set target data, and the system will automatically adjust the machine’s dynamic behavior accordingly.