High speed cutting processes medium application in the mould

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"High speed cutting " one word is not constant popularity in metallic treatment industry. It is mechanical manufacturer, cutting tool manufacturer no matter, or the firm that pursues metallic treatment be in zealous in discussing. Cutting of alleged high speed, it is with establishing milling cutter to make high speed rotates for broad sense, reach a machine tool to have cutting or treatment with the feed with high rate, and on the domain of disparate industry or application its definition differs somewhat. High speed cutting is not equal represent high yield or high production volume, but OK and affirmative is, this conduces to promotion output and concerned quality. In 20 centuries the demand of industry of 30 time aviation falls, the metal that be not iron (give priority to with aluminium alloy) component treatment amount increases gradually. Make an appointment with 1931, engineer of a Germany " Carl Salomon " put forward " high speed cutting is academic every are machined with tall cutting speed (5-10 the traditional cutting speed of times; It is with hard alloy cutting tool exemple, before traditional machine tool can touch the highest cutting rate that get to be 600 SFM [180m/min] about, and feed is 40IPM [1m/min] about) , drop the temperature when cutting bits to escape from point... " , the purpose is move with what this promotes material except rate, enhance productivity to need in order to deal with place. The technology that waits for each respect as a result of the metallurgy at that time, machine tool, control, cutting tool does not developed like nowadays, the primary level that can grind in explore only so. When be like promotion cutting speed, can wait in order to replace tall feed in order to increase the diameter of cutting tool, cutting blade number that increases cutting tool only, the effect is not ideal of course. Modern research still fails to confirm academic practicality completely, but high speed cutting can drop the temperature when cutting bits to escape from point however, aluminium and blame iron metal relatively iron qualitative alloy and cast iron have distinct effect (graph 1) ; This is OK the life that conduce adds cutting tool. Graph for metal of 1 pair of tall hardness, discharge treatment is one of the most effective treatment methods, but the time that discharge treatment needs is very long, and the control that the essence of finished product allows to spend the smooth situation that reachs the surface to wait is not easy, and the high temperature that when the property of the surface or local material will be discharged, produces (local can amount to 8, 000 ℃ or above) place change. Make as machinery, the progress of the technology such as system of control of electronic calculator, servo, the application of high speed cutting is able to mature with each passing day. Except metal of iron of applied Yu Fei, at going up century during 90 time more be introduced the treatment respect of iron metal and other alloy metal goes, and more be current makes a trade at the mould. Make cutting of complex three-dimensional high speed to the mould directly but greatly cut handling time (except of special to deep acupuncture point or other treatment) , and can obtain much better result; With high speed cutting electrode of treatment black lead can have much better get one's own back. High speed cutting also suits to machine compound component, if turbine adds the impeller of press and lamina,wait. And the high speed cutting that uptodate and general right at processing rolled steel applying is basic criterion: Be by the hardness of treatment material Rockwell 50 ℃ or above, exterior cutting speed is in 300m/min or above, can make up the feed rate that charge to be 25m/min or above. From the point of research and practice, with the 4 cuttings to 6 times tradition speed processes the rolled steel of tall hardness, already had not the expression of common, also can balance each square interest between, be like an user, the machine tool, manufacturer that controls a system to wait. "High speed cutting " the advantage that machines a respect in the mould and benefit pursue 21.

Classics is finite yuan of analysis (graph 2) and design production machine tool to compare a tradition want dainty a few, but provide stronger tigidity, can resist the dynamic change that shift of the quickness when high speed cutting brings, maintain the accuracy of displacement. 2.

Treatment bulk is more than 400 (long) X 400 (wide) X 150 (tall) the mould is provide economic benefits most. 3.

After classics heat treatment, hardness amounts to Rockwell the rolled steel of 63 ℃ , still can apply high speed cutting to make amend. 4.

Use the CAD software of cutting of appropriate high speed and control system, can make high speed cutting more fluent and suitable slippery. 5.

Use through collet of cutting tool of dynamic balancing amendatory (HSK type) reach integral sex hard alloy cutting tool, this conduce reduces pair of main shaft and the vibration that cutting tool causes, maintain the smoothness or evenness on rubber roll surface with due working face. 6.

Use proper scale to place hold establish milling cutter (the diameter that cutting tool is 2 times cutting tool in the least length inside knife clip) can increase its tigidity, decrease brace up quivering case appears; Undesirable chuck, or the phenomenon that improper locking will make cutting tool produces cock. The knife head that shrink sex designs, have stronger tigidity and homocentric sex, what reason conduce raises the appearance is bright and clean degree. 7.

The working length of cutting tool with short for beautiful, because deflection and length become direct ratio; In common treatment the circumstance falls, the length that cutting tool appears to be covered at clip is in diameter of 3 times cutting tool or the following when, will have relatively the working effect of beautiful (consider to machine circumstance place actually to need to reach the cutting that consults each cutting tool produces a proposal please please how-to or parameter) . 8.

Milling is different when the material of hardness, the coating of cutting tool also needs to make a consideration; If besmear the hard alloy cutting tool that has TiN or TiCN suits milling Rockwell hardness relatively 42 or the following alloy steel material, if besmear the hard alloy cutting tool that has TiAlN suits milling Rockwell hardness relatively the alloy rolled steel of 42 above, the horniness material that nitrogen of much brilliant cubic metre turns boracic coating razor blade to suit 60~65 of cutting Rockwell hardness relatively (the cutting that consults each cutting tool produces a proposal please how-to or parameter) . 9.

Use cutting tool of form of fast platoon bits (diameter and the scale that discharge bits chamfer length should be in 1~1.

5) , will prevent effectively to cut bits to pile up on labour tabulation face, reach the hot area with needless generation. 10.

When be being machined with cutting tool, the effective job diameter of workpiece of bring into contact with (Deff) (graph 3) come the rotate speed of operation main shaft, relatively will calculate with the diameter of cutting tool for beautiful. After computation gives optimal rotate speed, need the frequency of the point when considering cutting and workpiece contact, whether with natural frequency (2000Hz) generation is syntonic, make cutting tool generation needless brace up quiver influence workpiece surface. Graph 311.

The axial feed that uses dilettante formula (Ap) (graph 3) , conduce reduces the deflection of the bear of edge and cutting tool, but efficiency still can maintain; Every time the feed quantity of Ap, should not be more than cutting tool diameter 10% (thick cutting: 6~8% , in cutting: 4~6% , cutting of essence of life: 3% or the following; The cutting that consults each cutting tool produces a proposal please how-to or parameter) , but the precision that also needs to be being reached to machine place by the hardness of treatment material makes right amount adjustment. 12.

Radial feed (Ae; Pitch - P) (graph 3) the pliable situation that affecting workpiece surface; Ae should be less than effective cutting diameter 35% (thick cutting: 25~30% , in cutting: 15~20% , cutting of essence of life: 10% or the following; The cutting that consults each cutting tool produces a proposal please how-to or parameter) , but the precision that also needs to be being reached to machine place by the hardness of treatment material makes right amount adjustment. 13.

What feed will affect the life of cutting tool and workpiece surface is bright and clean degree; The feed of every blade is in as far as possible 0.

2~0.

02mm limits less than, and also be needed to consider by the coating of the hardness of cutting material, cutting tool and length (the cutting that consults each cutting tool produces a proposal please how-to or parameter) . 14.

Use oily mist means (the) of fluid of low viscosity cutting that compresses air to mix equal amount, with replacing a tradition agent cooling fluid reachs water to sweep means directly; Generally speaking, the viscosity of cooling fluid is taller, not certain can will cut bits to take away, and the likelihood goes up the adhere that cut bits in cutting tool, block up undertakes medium cutting. 15.

Imitate of cutting of the high-speed inside CAM system, but conduce decreases to produce needless mistake when high speed cutting. 16.

The user understands the importance that warm-up makes to main shaft before treatment, but after forgetting treatment however, make to main shaft drop in temperature the importance of working procedure. Although main shaft of general high speed movement already configured cooling device, the temperature that produces when the job with maintain or reducing main shaft (give priority to with the interior of main shaft) . But after the job with long classics, part of main shaft periphery and circumjacent temperature also have marked change; After reason main shaft quits the job, because both temperature difference circumstance increases, the water portion that this will make air medium is in main shaft crust apparently condense, rustily finally will be in measure less part without protection or motion apparently generation, indirect or affect a machine tool directly run. Suggest so, after machining be over, move main shaft put one safe position, with in reach low speed to run for nothing each 10 come minute, in order to lower the difference rate of difference in temperature, reduce the possibility that afore-mentioned circumstances produce thereby. High speed cutting is deferent to tool machine and data the demand that go up (＊ less important demand) 1.

Tall rigid baseplate must be provided induct oscillatory ability 2.

Limits of main shaft rotate speed: Make an appointment at 20, 000 Rpm (not under 10, 000 Rpm) 3.

Main shaft power: Make an appointment 22 KW 4.

But speed of process designing feed: 20~40m/min 5.

Move quickly: Make an appointment 40m/min 6.

Coordinate quickens or decelerate ability: Make an appointment with 1g 7.

Dictate a processing time: 1~20ms 8.

Aether net data is deferent speed: 250Kbits/s 9.

Increment size (linear) : 5~2 μ M 10.

Will carry out circular arc interpolation through NURBS 11.

Main shaft a person operating from within in coordination with outside forces is high temperature resistant reach tall stability, main shaft bearing has proper press beforehand reach refrigeration 12.

The difference of pluralism compensates by accident: On temperature (the mutual attrition when component of workshop, machine tool moves) , 13 ball silk lever.

Main shaft of be well versed in airs or high-pressured cooling fluid conveys systematic * 14.

Numerical control system matchs advanced job beforehand example of computation of cutting of check function * : Suppose 2 blade are globose establish milling cutter diameter (Dc) = 8mm; Radius C = 4mm and axial feed is measured (Ap) the 8% Ap = 8 X 0 that is cutting tool diameter.

08 = 0.

64mm reason ball establishs the Deff = 2 X [42 - (4 - 0 of effective job diameter of milling cutter.

640)2]0.

5 ≈ 4.

34mm assumes by the main shaft of reason of cutting speed Vc = 300m/min of cutting material fast X Deff] = [250 X 1000 / 3 of π of N = [Vc X 1000] / [.

1416 X 4.

34] ≈ 18, 500rpm hypothesis is globose establish milling cutter the feed Fz = 0 of every blade.

05mm; Blade counts the feed speed Vf = N X Fz X Z / 1000 = 18 of machine tool of reason of Z = 2, 500 X 0.

05 X 2 / 1000 = 1.

85m/min hypothesis radial feed [the 30% Ae = 0 that Ae] is effective job diameter.

3 X 4.

34 = 1.

3mm moves the Vr = Vf X Ap X Ae = 185 X 0 that divide an amount.

064 X 0.

1302 = 1.

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