In recent years, the needs of users who use cutting tools have also changed. In the past, it was widely believed that tools were consumables, so I wanted to reduce the cost of tools by reducing the amount of use. Recently, people's views have changed, and it is believed that the processing fee should be reduced by making full use of the role of the tool. This is also the view of the “processing halving movement†proposed by Hitachi Tool Company four years ago. In order to meet the changing needs of users, it is necessary for tool manufacturers to concentrate on developing more efficient tools.
This article will introduce the following: High-efficiency small-diameter solid carbide end mills (Epoch deep-cut round-end milling cutters) for finishing in the near future for mold processing needs; high-efficiency rounded corners for roughing Milling cutters (multi-edge large-feed rounded end mills); development, performance and machining examples of the latest super-lubricating coatings (JX coatings) that can significantly improve tool performance under high-efficiency machining conditions.
1. Solid Carbide End Mill "Epoch Deep Ending Cutter (Epoch Deep Radius)"
(1) Cutting performance
In recent years, the trend of replacing previous discharge machining with cutting has become more and more obvious, and this demand has gradually turned to cutting narrow and deep parts of the workpiece. When using an end mill to deep-cut such narrow and deep parts, the applicable mainstream tool is a small-diameter ball-end end mill (Hitachi tools are also producing Epoch deep-cut ball end mills, Epoch pen-type deep-cut ball heads). End mill series). However, when using a small-diameter ball-end end mill for high-efficiency deep cutting, the following problems occur (ie, cutting machining instead of electric discharge machining): 1 cutting resistance is easy to increase; 2 cutting speed at the center is difficult to increase (top The central blade portion is easily damaged; 3 there is a theoretical cutting residue (the tool radial cutting amount cannot be too large).
In order to solve the above problems, Hitachi Tools has developed a small diameter long neck series Epoch deep cutting round end mill. When using a small-diameter end mill for deep cutting, if the cutting resistance at the front end of the cutting edge of the tool is too large, vibration will occur and it will not be processed under high-efficiency cutting conditions, thus affecting the machining efficiency. Comparing the ball end mill and the R angle end mill from the viewpoint of cutting resistance, the latter has a small cutting edge contact area and a relatively small cutting resistance.
In addition, in the case of contour cutting, the ball end mill has a theoretical residual portion of the cutting, and in particular, the end chisel edge having a low cutting speed is easily broken. The rounded end mill can usually form a certain cutting surface when machining, so it has the advantages of stable and reliable processing.
The Epoch deep-cut round end mills are now developed to prevent chattering during deep cutting. In order to further improve the processing efficiency, a reverse tapered design is adopted. This design prevents the peripheral edge from coming into contact with the material to be cut due to the bending of the tool during the cutting process, thereby achieving stable machining. In addition, the tool coating uses a TH(TiSiN) hard coating with high hardness and high heat resistance and wear resistance, which is very suitable for direct deep cutting of high hardness materials.
The following describes the characteristics of the Epoch deep-cut round end mill by machining examples.
(2) Processing examples
1 groove efficient processing example
In order to efficiently process the groove, it is necessary to increase the step size in the XY direction to a certain extent. However, if the ball end mill is used for machining, the center blade which cannot increase the cutting speed is subjected to a large load and has to be lowered. Cutting conditions.
From the results of machining the groove using the ball end mill, it can be seen that if the set XY step is increased, the degree of damage at the center edge will also increase; if the set XY step is reduced, the cutting is reduced. Conditions, although no damage to the center edge was observed, the wear of the front center chisel edge increased. From the results of processing the groove using the Epoch deep-cut round end mill, it is known that the cutting is stable and the wear is reduced, and the groove processing effect on the high-hardness (about 50HRC) hot forging steel workpiece is good.
In this machining example, compared with the ball end mill, the processing time required for the new rounded end mill is shortened by about 1/4, and the processing cost is reduced by more than half.
2 deep cutting of high hardness materials
From the results of machining SKD11 cold work die steel (60HRC) with long neck end mill, it can be seen that the outer peripheral cutting edge of the ball end mill has great damage; while the Epoch deep machining round end mill has no damage, only uniform abrasion. It can be inferred that since the cutting edge contact length of the ball end mill is large, the cutting resistance is also large, and the outer peripheral cutting edge having a high cutting speed is easily damaged. This is the same as in Example 1, and the rounded end mill has obvious advantages.
Comparing the rounded end mills of Hitachi tools under the same processing conditions with other company rounded end mills, it can be seen that the rounded end mills produced by other companies do not use the inverted cone design, which is higher than 60HRC. The hardness material processing effect is not ideal. Hitachi Tools' new generation of deep-cut round-edged end mills have a unique design with an anticline shape, and the peripheral cutting edge is point-contact cutting. Even when machining high-hardness materials with straight-cutting, the cutting resistance is small. And the processing state is stable.
The processing example of Epoch deep-cut round-end milling cutter shows that the tool has excellent performance, especially for deep cutting of high hardness materials. In short, by fully utilizing the role of the rounded end mill, the material subjected to heat treatment and quenching can be directly grooved, and the processing cost is shortened, which can greatly reduce the processing cost. Experiments have shown that the processing efficiency of the rounded end mill can be increased by more than 5 times, and the processing cost can be reduced by 35%.
Next page
Laundry Sink,Laundry Room Sink,Kitchen Laundry Sink,Laundry Basin Sink
SALLY TECHNOLOGY CO.,LTD , https://www.sallyshowers.com