The development of the hottest milling in the fiel

2022-08-01
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The development of milling in the field of high-speed cutting

high-speed cutting is not a new thing. It has existed in many industries such as mold manufacturing for decades. As a process, it used to be regarded as the application of small tools in high spindle speed machine tools. However, today, high-speed cutting has been more widely used

high speed cutting (HS to point out what kind of m an enterprise should play at each stage)

thanks to the development of machine tool manufacturers, software developers, cutting tool manufacturers and the painstaking research of research institutions, high speed cutting (HSM) has a broader application space. The most important thing is that the actual process of high-speed cutting has not only stayed in theory, but really applied to all aspects of the workshop. The development of innovative milling tools makes high-speed cutting a more practical and profitable method in the mold manufacturing industry. Any cutting process criterion including high-speed cutting is that its effect should be as good as the machining ability of machine tools, software and cutting tools. In many years of practical application, the development of cutting tools in high-speed cutting is developing towards higher performance. Milling is an important part of high-speed cutting process. Its innovation has affected the performance of milling cutter in many die processing applications. In high speed cutting, speed is a key word, which represents spindle speed, cutting speed or feed speed. High speed cutting can be achieved by optimizing the milling process with high cutting speed or high feed rate

in the past, high-speed cutting mainly focused on high spindle speed, which can reach 8,, 000rpm. Many applications are experimentally driven by machine tools and the aviation industry, and the early high-speed cutting was mainly used in these aspects. However, in the workshop practice, the spindle speed during high-speed cutting is always kept in a very low range

in the 1990s, the development of high-speed cutting focused on the overall concept, including the creation of machine tools with a spindle speed of 200000rpm. High spindle speed and high feed speed are highly valued. Research institutions have proved that when the tool or machine tool parts do not match the application, high speed will bring serious consequences and high risks. The main factors to be considered are: cutting force, surface texture, metal removal rate, tool life and safety. These studies show the importance of optimizing high-speed cutting factors for the successful realization of high-speed cutting

new development of aluminum die milling

when talking about high-speed cutting and indexable tools, safe blade fixation is the top priority. The increasing high spindle speed of the milling machine and the feed of the worktable (especially in aluminum cutting) will bring high centrifugal force and the resulting heavy load on the blade fixing elements. The finite element method for analyzing the load distribution is particularly valuable when developing satisfactory solutions and quickly finding out the working model of indexable tools for high-speed cutting, and it can be used to design the best coolant channel and outlet structure, so as to help chip removal in the best way. This has produced a new generation of high-speed cutting tools for aluminum alloy cutting

coromill790 indexable end milling cutter is an example of cutting tool applied to high-speed machining of aluminum alloy. The end milling cutter is mainly used in high-speed machining processes such as cavity cutting, edge cutting, groove milling, profiling and so on. The blade is fixed by the specially developed blade body interface. The design of the serrated contact surface between the bottom of the blade groove and the back of the blade not only maximizes the safety in high-speed milling, but also ensures the machining accuracy. The force on the blade is uniform, which makes the machining more smooth and safe, and extends the service life of the tool. The above design greatly enhances the cutting quality and improves the machining capacity

coromill 790 end milling cutter serrated contact surface design can also be widely used in face milling cutters used in aluminum processing, especially cast aluminum parts, such as molds, engine sets, gearbox shells, etc. From semi finishing to ultra finishing, when the cutting speed is increased to 8000m/min, the positive rake blade of coromill 790 end mill can be made of cemented carbide, polycrystalline diamond (PCD) and cubic boron nitride (CBN). This design makes the milling cutter widely applicable to aluminum alloy cutting and even cast iron cutting. The structure of the high-tech coromill 790 end milling cutter is not complex, its blade axial adjustment is simple and convenient, and it also has the advantages of cutting force balance, wide application fields, accurate machining allowance control, etc

replaceable solid carbide cutting tools

solid carbide cutting tools, especially small-diameter tools, are widely used in die cutting of various materials. Between indexable inserts and solid carbide cutters, there is now an alternative third solution. This solution can cover the characteristics of the former two to some extent. It not only provides the indexability of cutting edges, but also provides the benefits of using small and medium-sized solid carbide end mills. So far, the prospect of this field has been evaluated, and its potential advantages and disadvantages have been pointed out. However, a new tool concept can more fully develop this field

although the indexable blade technology can provide many advantages, especially in the case of small tool diameter, the modern integral cemented carbide cutting method with long radial cutting edge and axial feed capacity provides very important advantages, including high precision, high surface quality, cutting performance and light cutting effect. The use of indexable blade tools only needs to quickly replace the cutting part of the tool. Optimizing the performance of this part can increase the use advantage

the minimum diameter of the indexable blade end milling cutter is 12mm. When it is less than this diameter, the installation and clamping of the blade become impractical. On the other hand, the diameter of solid carbide end mills can be as small as 1mm or less. The diameter of MM is common to both types of end mills, but the temperature range for checking the cooling rate is different, which can be widely used in many processing procedures. The replaceable end milling cutter perfectly combines the indexable blade with the integral cemented carbide. The indexable blade can use mxene to attract a wide range of interests from rough machining to semi finishing with high production efficiency, and the integral cemented carbide is used for semi finishing to super finishing. As the third option, the end milling cutter with detachable head has the potential to be optimized in the cross application field of the two

The key part of the coromill 316 replaceable head tool is the interface between the cutting head and the tool body. One of the most important parts of the interface is a specially developed and patented self centering thread, which is used to pull and hold the top into the tool handle (used to tighten the tool head and tool body) without any clearance. The axial support surface is as large as the radial support surface, and the inner end of the cutting head is supported inside the tool handle along the conical surface, so as to provide the highest bending strength. The cutting head of the cutting tool can be easily fixed and tightened by turning the wrench a little. The unique interface between the cutting head and the tool handle provides high rigidity for the full groove rough machining process and high precision for the precision finishing process. The coromill 316 tool has axial tool length repeatability and radial runout limited to 0.02 mm

coromill 316 tool has a balanced design, so it can use a relatively high spindle speed. The combination of high speed and multi tooth cutting head provides very high feed rate and high cutting speed. The concept of replaceable head also makes the tool groove shape easily adapt to the workpiece material without too much consideration of tool stability. The tool stability of traditional integral cemented carbide tools will be affected by the core diameter

blade grades for higher speeds

when discussing blade grades for indexable milling cutters, high-speed cutting requires the use of blade grades with higher performance, especially when production efficiency needs to be given priority over cutting versatility. When the metal removal rate and machining cycle need to be given priority in die milling and the cutting conditions are good, the performance of the general brand may not be good enough. When high cutting speed, long-time contact and harder materials are used, more and more severe phenomena such as crater wear, thermal cracks and plastic deformation may occur, which will reduce the service life and predictability of the tool

in order to obtain higher machining safety when improving cutting parameters, the requirements for wear resistance are obviously higher than those for toughness. Therefore, in order to make the blade harder, ISO P20 blade grade should be considered in steel mold applications. This is to avoid premature breakage of the cutting edge, so as to obtain higher cutting parameters. In order to further improve the cutting performance, it is generally considered not to use any coolant in the milling of steel dies

since high cutting rate is widely used nowadays, even if the amount of coolant is large, it is difficult to have a significant impact on the cutting edge, so dry milling should be used. During wet cutting, most of the coolant is evaporated, and the remaining coolant can only play an intermittent role in cooling the blade when it enters and exits. At this time, the heat change is amplified, which will have a worse impact on the blade than the actual high temperature. Modern coating grades are specially used for high-speed milling of steel. They have the ability to provide high safety without coolant under high cutting speed and high feed conditions. However, most brands can work well under dry and wet processing conditions

high speed and high feed means more heat. However, the use of steel milling grades such as gc4220 will not be a negative factor. It is an ISO P20, CVD coating brand designed to achieve the highest performance through high cutting parameters. Some processes require higher production efficiency than versatility, so they require higher wear resistance. Perhaps this is also one of the ways to deal with harder steel. Therefore, the heat related wear mechanism becomes a more priority problem, and a brand that can withstand the damage of this cutting edge is required. Gc4220 has become the first choice to shorten the cutting time through higher cutting speed. It has a wide range of applications. It has even become an optimizer for many steel mold materials and a good choice for cast iron milling with high heat problems

faster feed and higher speed under small cutting depth

nowadays, in many mold workshops, the trend of NC milling is to use higher feed rate and smaller cutting depth for processing after rough machining. This is beneficial to the machine tool because it improves the machining results. Power limitation is also an increasingly important factor to consider, especially on machining centers with iso40 and 30 taper. The higher speeds and feeds of today's machine tools also mean that small-diameter milling cutters can be used more efficiently and the square shoulders and end faces can be cut through repeated tool runs. These factors help to set the development direction for the new generation of square shoulder milling cutters. Therefore, in the new coromill milling cutter series, the maximum depth of coromill 490 milling cutter should be at the lower value: 5.5mm, and the recommended value is 4mm. This also provides an opportunity for new square shoulder milling cutters equipped with square blades, and is also the basis for obtaining high blade stability and good tool economy through accurate and safe blade positioning

coromill 490 blade has optimized the blade support point and placed it as far away as possible along the edge of the cutterbed, so as to minimize the impact of the cutting force, which can easily make the blade on the cutterbed move. Compared with the long cutting edge, the small cutting depth tends to magnify the lever effect with the blade screw. However, the structure of the coromill 490 compensates for this and ensures high stability

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