25 FAQs in the hottest mold manufacturing field 3

25 FAQs in mold manufacturing (3)

22) what are the practical advantages of high-speed cutting

the tool and workpiece can maintain low temperature, which in many cases extends the life of the tool. On the other hand, in the application of high-speed cutting, the cutting amount is shallow, and the cutting time of the cutting edge is particularly short. That is to say, the feeding time is faster than the heat transmission time

low cutting force results in small and consistent tool bending. This, combined with the constant machining allowance required by each tool and process, is one of the prerequisites for efficient and safe machining

because the typical cutting depth in high-speed cutting is shallow, the radial force on the tool and spindle is low. This reduces the wear of spindle bearings, guide rails and ball screws. High speed cutting and axial milling are also a good combination, which has a small impact on the spindle bearing. Using this method, you can use tools with long overhang and little risk of vibration

high productivity cutting of small-size parts, such as rough machining, semi finishing and finishing, has good economy when the total material removal rate is relatively low

high speed cutting can obtain high productivity and excellent surface quality in general finishing. The surface quality is often lower than RA 0.2 um

high speed cutting makes it possible to cut thin-walled parts. Using high-speed cutting, the cutting time is short, and the impact and bending are reduced

the geometric accuracy of the mold is improved, and the assembly is easier and faster. No matter who you are and how skilled you are, you can get the surface texture and geometric accuracy produced by cam/cnc. If you spend a little more time on cutting, the time-consuming manual polishing work can be significantly reduced. It can often reduce up to%

some machining, such as quenching, electrochemical machining and EDM, can be greatly reduced. This will reduce investment costs and simplify logistics. By replacing EDM with cutting, the service life and quality of the die are also improved

with high-speed cutting, the design can be changed quickly through cad/cam, especially when there is no need to produce new electrodes

23) are there risks or disadvantages of high-speed cutting

due to the high acceleration, deceleration and stop in the initial process, the guide rail, ball screw and spindle bearing produce relatively fast wear. This often leads to higher maintenance costs

special process knowledge, programming equipment and interface for fast data transmission are required

it may be difficult to find and select senior technical staff. B1.01

there is often a long debugging and failure time

there is no need for emergency stop during processing, resulting in human errors and software or hardware failures, which will have many serious consequences

there must be a good processing plan to provide food to hungry machine tools

safety protection measures must be taken: use machine tools with safety covers and debris proof covers. Avoid large overhang of the tool. Do not use heavy tools and extension rods. Regularly check whether the tool, extension rod and bolt have fatigue cracks. Only use the tool with the highest spindle speed indicated. Do not use HSS Cutters

24) what are the requirements of high-speed cutting for machine tools

typical requirements for iso/bt 40 machine tool are as follows:

spindle speed range spindle power 22 kW

programmable feed rate m/min

rapid traverse axial deceleration/acceleration 1 g

block processing speed milliseconds

data transmission speed 250 kbit/s (1 millisecond)

incremental (linear) fertilizer implementation area of more than 35 million mu

or NURBS interpolation

the spindle has high thermal stability and rigidity, The spindle bearing has high pretension and cooling capacity

air supply/coolant through the spindle

rigid machine tool frame with high vibration absorption ability

various error compensation temperatures, quadrants, ball screws are the most important

advanced foresight function in CNC

25) what are the typical characteristics or requirements of cutting tools for high-speed cutting

integral cemented carbide:

high precision grinding, radial runout less than 3 microns

minimum protrusion and overhang, maximum rigidity, minimum tool bending deformation and large core diameter

wipe the rust inhibitor coated on the machined surface on the machine. In order to minimize the risk of vibration, cutting force and bending, the cutting edge and contact length should be as short as possible

oversize and taper tool handle, which is particularly important in small diameter

fine grain matrix and TiAlN coating with high wear resistance

inner cooling hole for air cooling or coolant

strong micro groove shape suitable for high-speed cutting of hardened steel

symmetrical tools, it is best to design to ensure balance

tools using indexable blades:

balance guaranteed by design

high precision with small runout on the blade base and blade, and the maximum radial runout of the main blade is 10 microns

the grade and groove shape suitable for high-speed cutting of hardened steel

the cutter has proper clearance to avoid friction when the bending (cutting force) of the cutter disappears

cooling hole (end mill) for supplying additional air or coolant

knife is specifically marked with the maximum allowable speed