The application of profile modeling milling cutter

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  • source:LAURENDA CNC Machining
There always can be vibration when dislocation milling cutter processes work, in the workshop, can feel the familiar sound that brings to vibration and sense. When the cutting depth that should have through increasing a sword will raise metallic cutting to lead, often can damage the blade of cutting tool is pointed, shorten the life of the machine tool. Besides improving machine tool performance, still a kind of method can improve treatment condition, that uses profile modeling milling cutter namely. This kind of cutting tool says to do again " button cutting tool " . Profile modeling milling cutter just is in establish milling cutter traditionally there is a simple change on the foundation, differ with traditional lozenge razor blade or quadrate razor blade, profile modeling milling cutter uses circular bit. This change makes profile modeling milling cutter has a variety of advantages, among them it is current that major benefit can say small cut deep, big feed, with high speed treatment develops a complement below the trend. The article will introduce these advantages respectively: Feed ability forces strong helix mill and intensity of blade of cutting of oblique plane process capability are higher more cutting blade participate in the rough machining feed that tall cutting rate obtains to approach precision work below treatment low power milling cutter of a few profile modeling can resemble broach in that way, direct feed, cut work. Be like: Carry milling cutter of profile modeling of milling cutter type, but it is OK to accept the gift when having enough space in cutting tool extreme in manufacturer only along this direction cutting. Milling cutter of the profile modeling that cover type also can cut work directly, but the power when treatment is used up very big. Profile modeling milling cutter replaces broach impossibly, the area that because get,treatment participates in when cutting is larger, exceeded this kind of cutting tool can susceptive cutting deepness. But the issue that profile modeling milling cutter can cut the ability of workpiece this kind to solve a your poll in treatment to ache directly: That needs to drill an initiative hole beforehand before rough machining namely. Because common but dislocation establishs milling cutter to cannot cut material directly along Z axis, so need drills an initiative hole beforehand. Method of another kind of feed is to pass a cant to enter, normally software of need application CAM is finished. And milling cutter of use profile modeling, this one pace is OK leave out. But the feed operation cutting tool and model antrum treatment is made up for a whole process, need not the feed problem of special consideration cutting tool. This kind but the means of free feed to complex model the rough machining of antrum, and call routine of exterior rough machining very useful. It is OK that helix interpolation applies profile modeling milling cutter and helix interpolation integratedly easy, apace machines big diameter aperture. This kind of technology is similar to whorl milling, 3 axes (X, Y, Z) move at the same time. But it is different from helix milling again, because use treatment of profile modeling milling cutter not to need initiative opening, can cut material directly. In addition, because profile modeling milling cutter has big hind horn, litre of horn in helix interpolation process is OK very big, and need not fear meeting attrition arrives the bottom of cutting blade. This process that goes easily simply brings a lot of profit, the cutting tool that can use identical diameter machines the aperture of different measurement, require the process of metabolic be classified hole size only. A typical contrast can explain this kind of technology has the latent capacity that increases efficiency. Because cutting blade intensity does not have pointed horn, be in but in razor blade of dislocation hard alloy, the cutting blade intensity of circular razor blade is highest. Because this can be used at heavy cut, perhaps do not stabilize the rough machining below the condition. Use when need long model when cutting tool, circular razor blade can bear bigger cutting tool deflexion and vibration, rotate speed increases in allowing to machine, increase feed, reduce the risk of collapse blade at the same time. Graph 1: Cutting deepness hour, efficiency of circular razor blade is taller, cut lesserly deep decreased to cut the ply that be like, the power that needs accordingly is low also. Graph 2: Profile modeling milling cutter is used axial reduces role, can make cutting smooth, the bearing of cutting blade is better also when use circle razor blade, cutting force can get distributinging effectively. And the orthogonal milling cutter to the model, cutting tool pressure basically is radial load, this brought about cutting tool to be out of shape big, raised the possibility of vibration and cutting tool damaged. Circular cutting blade disperses equably cutting force, force of more axial of cutting force translate into. What when this uses lengthen cutting tool just about, hope, because decrease trail,also reduced cutting tool to be out of shape to force. But should take care when use horizontal machining center. The addition of axial force may make install in the machine tool the clamping apparatus on horny board appears bending, because,this is this structure unlike go up in vertical machining center when firm in that way. On horizontal machining center, bending can bring vibration, can bring about bit to appear then slight collapse blade. Cutting tool life can shorten because of this, the possibility of cutting tool damaged is increased. To decrease or prevent this kind of situation, should use the cutting tool of the horn before axial, can reduce the force that turns downward to workpiece so. Razor blade of circle of cutting blade amount still has an advantage to have blade of more practicable cutting than common hard alloy razor blade namely. According to the dimension of bit and cutting deepness, circular razor blade can have 4 to arrive 8 times effective dislocation, double material purify quantity is common lozenge and quadrate razor blade at least. This kind of advantage can reduce handlers to go the time that tool room changes new bit (the effective working hours that assured handlers) , the goods in stock that reduced bit is measured (reduce stock cost) , reduced the cost of every cutting blade. For example, price of average lozenge razor blade is 8 dollars about, have blade of two usable cutting, the cost of every cutting blade is 4 dollars. The cost of quadrate razor blade is 10 dollars, arrive so on average every cutting blade is 2.

5 dollars. Compare the cost of these razor blade and circular razor blade, every price can achieve circular bit 11 dollars (below most circumstance even less) . Be in suppose the most abominable condition - heavy cut - next treatment, bit is only OK dislocation 4, the cost of every cutting blade is 2.

75 dollars. Below more circumstances, can dislocation 8, so the cost of every blade is 1.

38 dollars. Compare through actual application and cost, the metallic cutting rate that circular razor blade compares other type razor blade not only is high, its economy also has appeal quite. If tall cutting rate, feebleminded bad news is used appropriate, circular razor blade can have very high metallic cutting rate, and do not need very high machine tool power. Because the intensity of circular razor blade is high, work can be processed below the feed rate that cannot achieve in orthogonal milling cutter, allow to undertake the rough machining of bigger load on light-duty machine tool even. The crucial question that needs knowledge is: Cutting deepness is bigger, cut bits thicker also, this uses up those who increase power (see a picture 1) . Use shallow cutting - cutting deepness is 0.

025 to 0.

050 inches - cutting tool of common circular razor blade can be in 0.

040 inches every tine feed processes rolled steel below rate, certain moment, still can achieve 0.

06ipt. And the maximum of major lozenge razor blade and quadrate razor blade has 0 only.

010-0.

012ipt. Notable is, the use person of cutting tool of a few button can encounter such problem, in machining a process, or it is bit after wearing away, bit can be in the installation of cutting tool inside produce shift. Because pressure of cutting tool susceptive is too great,these two kinds of circumstances are, the clip that exceeded bit clamping unit holds power. Because this needs,consider the case of likelihood happening integratedly when designing cutting tool. For instance, while some cutting tool are using bolt to secure bit, there still is a small pincers above, the means of this kind of double clamp ensured the safety of bit. If pursue,profile modeling establishs the construction of milling cutter: 1.

Coping pincers assures the clamp of bit: 2.

the horn before axial is OK bearing cutting blade; 3.

The facet on bit uses Yuzheng to be decided to the lock; 4.

The bit that worries via blade assures to machine precision; 5.

Adjacent razor blade provides feed capability another serious problem is bit installation deciding a function to the lock. User of cutting tool of a lot of button uses cheap Die Casting bit, smooth round face cannot radial lock is decided. Action can bring about the bolt loss torque on bit in force of cutting of bit tangent direction. Profile modeling milling cutter solves this problem through locking scale raising in bit flank - the locking face of locking face and cutter hub cooperates cheek by jowl, make lowest falls relative to athletic possibility between both. When wanting to undertake big feed leads cutting, need cutting tool can provide the greatest bearing power to cutting blade. The profile modeling milling cutter of the horn before using negative axial (let bit tilt downward, front workpiece) , with conservative treatment parameter, can achieve good treatment result, but can fail when feed rate is very old. Itself of this kind of design has drawback, the main area that gets power in cutting blade lacks bearing (see a picture 2) . Use the profile modeling milling cutter of the horn before axial can offer very good bearing to cutting blade, because the hard alloy at the back of cutting blade and cutting force are close to Yu Ping to go,this is. This kind of means uses hard metal, can let an user experience hard alloy to absorb the capacity that controls stress. But below this kind of circumstance, the stiffness of cutting tool clamp is very important. Because this is recommended strongly,use short model establish milling cutter collet to perhaps cover collet of type milling cutter. Use proper treatment, even if have 10 only or the machine tool of 15 horsepower, also can obtain competitive cutting, and reduce setting measure, the manufacturing arrangement of the factory is more agile also. The rough machining that approachs precision work uses circular bit at rough machining, it is better to was offerred to semifinishing machining or finish machining " preparation works " . Undertake rough machining with orthogonal milling cutter, when be down cutting, can take next step. Each cutting depth that takes a knife is bigger, effect of this kind of step is more apparent. The cutting tool when surface of workpiece of this kind of cobbly can bring about semifinishing machining gets power not all, bring concussion to cutting tool, bring about cutting tool to be out of shape, transfer impossibly directly from rough machining so finish machining. Need semifinishing machining not only, and have precision work for many times even. Use circle razor blade reduced the happening of afore-mentioned circumstances greatly. Leave chance to extricateoneself from an awkward position in that way unlike orthogonal cutting tool, and have a few only very small " drape " , and height is very low, machine easily. In cutting deepness little state of affairs falls, circular razor blade also is optimal choice, "Drape " height becomes smaller, the workpiece surface after rough machining compares level, can undertake semifinishing machining very easily. Certain moment, can have precision work directly even. The comparison of helix interpolation cycle shows like plan institute: Workpiece material is 4140 steel, the diameter is 4 inches aperture, use diameter is 1 inch profile modeling milling cutter, rotate speed is 4000rpm, feed 200ipm, cutting deepness is 0.

035 inches generally speaking, the factory establishs milling cutter to machine big diameter aperture with broach and circular arc interpolation. For instance, in the milling on the vertical machining center of a 15 horsepower with this kind of method a diameter is 4 inches, deep 3 inches aperture. It is with the diameter first 1.

25 inches but dislocation broach gets a via, cost only 1.

5 minutes. Be 1 inch with the diameter next but dislocation establishs milling cutter, program of closed circuit of interpolation of moving circular arc undertakes machining, treatment parameter is: Cutting deepness is 0.

1 inch, cutting width is 0.

7 inches, turn up 2300rpm, feed rate is 25ipm. The treatment cycle of circular arc interpolation is 35 - 45 minutes, total handling time achieves two kinds of such cutting tool 45 minutes. Now, the means that uses helix interpolation on same table machine tool machines same hole. Use what be 2 inches of the diameter of circular razor blade to cover type to establish milling cutter. Hypothesis cutting tool has 4 blade, the inscribed circle diameter of bit is 0.

5 inches. Typical treatment parameter is: Rotate speed is 1500rpm, feed rate is 61ipm, cutting deepness is 0.

06 inches, helix treatment reachs point of 4 inches of diameters. About 50 loop hind are OK mill wears workpiece, walk along a knife 5 times to be able to reach the central line of bit again, completed treatment namely. Every diameter that takes a knife is equal to the difference of 4 inches of aperture and diameter of 2 inches of cutting tool, namely 2 inches. The total length that cutting tool place runs is encircled for every 6.

28 inches (the circumference that the diameter is 2 inches circle) multiply with 55, namely 345 inches. When feed quantity is 61ipm, handling time needs 5.

5 minutes. In other words, the helix interpolation in this example can make handling time shortens 87 ％ , and managing a knife. CNC Milling