A case study of CAD/CAM software ‘CAM-TOOL’ exclusively for molds & dies Contributing to quality improvement and cost reduction in the manufacture of molds for plastic injection molding

13/03/2023

SAMURAI ASIA Editorial Department

T.KRUNGTHAI INDUSTRIES PUBLIC CO., LTD. (hereinafter referred to as TKIP) is a leading manufacturer of plastic parts for the automotive and electrical appliance industries in Thailand, and has been trusted by major manufacturers in Thailand and abroad for almost 50 years since 1973. The company has three manufacturing plants in Thailand

・Chachoengsao Plant: Produces plastic parts for automobiles and molds for plastic parts molding, with an annual production capacity of up to 100 molds.
・Samut Prakan Plant: Mainly produces plastic parts for automobiles
・Prachinburi Plant: Produces plastic parts for automobiles and electrical appliances

▲ Automotive parts and electrical appliances parts manufactured by TKIP

In this interview, we spoke with Mr. Gowe, MD of TKIP and Mr. Girayut, Manager of Mold Manufacturing, about the project to implement CAM-TOOL in mold manufacturing at the company's Chachoengsao Plant.

CGS Asia, T.KRUNGTHAI, TKT

▲ Third from left: MD Mr. Gowe, Fourth: Mr. Girayut

Launch of problem-solving project with CGS Asia to improve production efficiency in mold manufacturing

TKIP has a manufacturing policy of quality-oriented mold manufacturing and cost reduction.
1. Development of technology and human resources to produce high-quality molds
2. Fault-free, high-quality machinery and equipment to reduce lost time
3. Adoption of appropriate software for mold manufacturing systems

In order to increase production efficiency while complying with these requirements, CGS's CAM-TOOL was introduced to solve the following problems in mold manufacturing.

・The surface of the parts is uneven and there are cutter marks.
・It takes time to polish parts, and repeated polishings required.
・Mold tools in the end milling process are prone to breaking and deterioration.

Cutter Mark, Improving mold quality, CGS Asia

▲Example of uneven surface and cutter marks

Broken mold tool, Improving mold quality, CGS Asia

▲ Sample of broken mold tool

▲ Special Tool

▲Tooling DB

Solving problems with various functions of CAM-TOOL
Mold quality improvement & significant reduction of work time

CGS established a joint engineering team with the company and proposed the following solutions.

Issue 1: Uneven part surfaces with cutter marks
⇒ solved by the "Aiming Check" function
A function that can generate curved surface CL according to the shape of the model by processing along the wall of the mold shape. Fine adjustment of accuracy up to 0.1 microns is possible.

Cutter Mark, Improving mold quality, CAM-TOOL, CGS Asia

▲ Mold surface sample using CAM-TOOL's Aiming Check function

Issue 2: Polishing parts takes a long time and requires repeated polishing
⇒ solved by the "Surface Calculation" function
This function has a polygon mode for high-speed milling that is ideal for milling rough parts, and a surface mode for milling that allows the user to fine-tune the level of accuracy as desired. The part surface is finished smooth, eliminating the need for repeated polishing. Polishing time can be reduced by up to 20%.

CAM Engine, CAM-TOOL, การแก้ปัญหาแม่พิมพ์, ปัญหาชิ้นงานไม่เรียบ, CGS Asia

▲ Sample of machined cross section using the "Surface Calculation" function

Issue 3: Mold tools are prone to breaking and deterioration in the end mill process
⇒ Solved by using the "Tool Database" to generate data for chip-replaceable tools
CAM-TOOL is equipped with a "Tool Database", which is an information and catalog of various brands of cutting tools and holders that can be additionally drawn within CAM-TOOL. By not requiring input of information such as cutting tool sizes and part cutting processes, the information in the database can be used as is, which is expected to reduce human error.

Successfully improved work accuracy and shortened processes by implementing CAM-TOOL Satisfied with after-sales support as well

"We are committed on the development and manufacture of high-quality, low-cost molds. The introduction of CAM-TOOL has improved our work accuracy, shortened our production process, and enabled us to accurately detect errors that cannot be found by visual inspection. We would like to express our sincere gratitude to CGS Asia for helping us improve the quality and reduce the cost of our mold production," says Mr. Gowe, MD of TKIP

"In our mold manufacturing, there were issues such as coating costs and long hours of work due to problems such as long polishing times and uneven surfaces. Through this initiative with CGS Asia, we have recognized the convenience of CAM-TOOL, which has considerably improved the work speed at our worksites. For example, by utilizing the Surface Mode on part surfaces, we no longer need to repeatedly cut the product, allowing us to complete the job in a single process. CGS Asia has been very cooperative and supportive on a daily basis, and we have been pleased with the detailed training the company have provided to our on-site staff. If any problems should occur, it responds promptly and is a reliable partner," says Mr. Girayut, TKIP mold manufacturing manager.

In cooperation with: T. KRUNGTHAI INDUSTRIES PUBLIC COMPANY LIMITED

Established in 1973, the company is a leading Thai manufacturer of plastic parts for automobiles and electrical appliances. It also produces molds at its three plants in Thailand. It employs more than 1,000 people and has 90 plastic injection molding machines, as well as staff dedicated to manufacturing plastic injection molds.

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