Aluminum mold milling in the field of high-speed cutting new development
2018-04-26 09:00:33
In the past, high-speed cutting focused on high spindle speeds, which ranged from 8,000 to 100,000 rpm. Many applications are experimentally driven by the machine tool and aerospace industries. Early high-speed cutting applications mainly applied these aspects. However, in the workshop practice, the spindle speed during high-speed cutting is always kept in a very low range.
High-speed cutting is not new. It has existed in many industries such as mold manufacturing for several decades. As a process, it was previously considered to be the application of small tools on high spindle speed machines. However, today, high-speed cutting has a wider application. In the 1990s, the development of high-speed cutting focused on the overall concept, including the creation of machine tools with spindle speeds of 200,000 rpm. High spindle speeds and high feed rates are highly valued. Research institutes have proven that high speeds can have serious consequences and extremely high risks when tools or machine parts do not match the application. The main factors to consider are: cutting force, surface texture, metal removal rate, tool life, and safety. These studies show the importance of optimizing high-speed cutting factors for successful high-speed cutting.
Thanks to the intensive research of the development and research institutions of machine tool manufacturers, software developers, and cutting tool manufacturers, high speed cutting (HSM) now has a broader application space. More importantly, the actual process of high-speed cutting has not only stayed in theory, but is actually 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 rule, including high-speed cutting, requires that the effect be as good as that of machine tools, software, and cutting tools. In many years of practical application, the development of tools in high-speed cutting has been moving toward higher performance. Milling is a key part of the high-speed cutting process, and its innovation has affected the performance of milling cutters in many mold processing applications. In high-speed cutting, speed is a key word and it represents spindle speed, cutting speed, or feedrate. High speed cutting can be achieved by optimizing the milling process with high cutting speeds or high feedrates.
New Developments in Aluminum Milling When it comes to high-speed cutting and indexable tools, secure blade fixing is a top priority. The ever-increasing milling machine's high spindle speed and table feed (especially when aluminum cutting is carried out) bring about high centrifugal forces and the resulting large loads on the blade holding elements. The finite element method for analyzing load distribution is particularly valuable when developing a satisfactory solution and finding a working model for indexable cutting tools for high-speed cutting more quickly, and using it to design better cooling The liquid passage and the outlet structure, in order to help chip removal in a better way. This resulted in a new generation of high-speed cutting tools for aluminum alloy cutting.
The CoroMill 790 indexable end mill is an example of a tool used for high-speed machining of aluminum alloys. This type of end mill is mainly used in high-speed machining processes such as cavity cutting, edge cutting, slot milling, profiling, etc. in mold making. The fixing of the blade is achieved by a specially developed blade-knife body interface. The serrated contact surface design of the bottom surface of the blade slot and the back surface of the blade not only greatly improves the safety in high-speed milling processing, but also ensures the processing accuracy. . The uniform force of the blade makes the process smoother and safer, and the service life of the tool is extended. The above design greatly enhances the cutting quality and improves the processing capability.
The serrated contact surface design of the CoroMill790 end mill can also be used extensively in face milling cutters used in aluminum machining, especially for cast aluminum parts such as dies, engine blocks, gearbox housings, etc. From semi-finishing to super-finishing, when the cutting speed is increased to 8000m/min, the front rake insert of the CoroMill 790 end mill can use carbide, polycrystalline diamond (PCD), cubic boron nitride (CBN). This design makes the milling cutter widely applicable to aluminum alloy cutting and even cast iron cutting. The high-tech CoroMill 790 endmill structure is not complicated. Its blade axial adjustment is simple and convenient. It also has the advantages of balanced cutting force, wide application field, and precise control of the machining allowance.
Replaceable Head Solid Carbide Tool Solid Carbide cutting tools, especially small diameter tools, are widely used in die cutting of various materials. Between the indexable insert and the solid carbide insert, there is now an alternative third solution that can to some extent cover the characteristics of the first two, which provides both cutting The indexable nature of the edge provides the benefits of using a medium and small diameter solid carbide end mill. Until now, the outlook for the field has been evaluated, pointing out its potential advantages and disadvantages. However, a new tool concept can fully exploit this area.
Although indexable insert technology offers many advantages, modern solid carbide cutting methods with long radial cutting edges and axial feed capability are important, especially when the tool diameter is small. The advantages include high precision, high surface quality, knife performance and light cutting action. The use of indexable insert tools only requires quick and easy replacement of the cutting part of the tool, optimizing the development of this part of the performance, can increase the use of advantages.
The diameter of the indexable insert end mill is as small as 12 mm. Below this diameter, blade installation and clamping become impractical. On the other hand, the diameter of solid carbide end mills can be as small as 1 mm or less. The 10-25mm diameter is a range that both types of end mills have and can be used in a wide range of machining processes. Replaceable head end mills combine indexable inserts with solid carbide, indexable inserts for high-throughput roughing to semi-finishing, solid carbide for semi-finishing to super-finishing Processing. As a third option, the head-removable end mills have the potential for optimization in the cross-application of the two.
High-speed cutting is not new. It has existed in many industries such as mold manufacturing for several decades. As a process, it was previously considered to be the application of small tools on high spindle speed machines. However, today, high-speed cutting has a wider application. In the 1990s, the development of high-speed cutting focused on the overall concept, including the creation of machine tools with spindle speeds of 200,000 rpm. High spindle speeds and high feed rates are highly valued. Research institutes have proven that high speeds can have serious consequences and extremely high risks when tools or machine parts do not match the application. The main factors to consider are: cutting force, surface texture, metal removal rate, tool life, and safety. These studies show the importance of optimizing high-speed cutting factors for successful high-speed cutting.
Thanks to the intensive research of the development and research institutions of machine tool manufacturers, software developers, and cutting tool manufacturers, high speed cutting (HSM) now has a broader application space. More importantly, the actual process of high-speed cutting has not only stayed in theory, but is actually 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 rule, including high-speed cutting, requires that the effect be as good as that of machine tools, software, and cutting tools. In many years of practical application, the development of tools in high-speed cutting has been moving toward higher performance. Milling is a key part of the high-speed cutting process, and its innovation has affected the performance of milling cutters in many mold processing applications. In high-speed cutting, speed is a key word and it represents spindle speed, cutting speed, or feedrate. High speed cutting can be achieved by optimizing the milling process with high cutting speeds or high feedrates.
New Developments in Aluminum Milling When it comes to high-speed cutting and indexable tools, secure blade fixing is a top priority. The ever-increasing milling machine's high spindle speed and table feed (especially when aluminum cutting is carried out) bring about high centrifugal forces and the resulting large loads on the blade holding elements. The finite element method for analyzing load distribution is particularly valuable when developing a satisfactory solution and finding a working model for indexable cutting tools for high-speed cutting more quickly, and using it to design better cooling The liquid passage and the outlet structure, in order to help chip removal in a better way. This resulted in a new generation of high-speed cutting tools for aluminum alloy cutting.
The CoroMill 790 indexable end mill is an example of a tool used for high-speed machining of aluminum alloys. This type of end mill is mainly used in high-speed machining processes such as cavity cutting, edge cutting, slot milling, profiling, etc. in mold making. The fixing of the blade is achieved by a specially developed blade-knife body interface. The serrated contact surface design of the bottom surface of the blade slot and the back surface of the blade not only greatly improves the safety in high-speed milling processing, but also ensures the processing accuracy. . The uniform force of the blade makes the process smoother and safer, and the service life of the tool is extended. The above design greatly enhances the cutting quality and improves the processing capability.
The serrated contact surface design of the CoroMill790 end mill can also be used extensively in face milling cutters used in aluminum machining, especially for cast aluminum parts such as dies, engine blocks, gearbox housings, etc. From semi-finishing to super-finishing, when the cutting speed is increased to 8000m/min, the front rake insert of the CoroMill 790 end mill can use carbide, polycrystalline diamond (PCD), cubic boron nitride (CBN). This design makes the milling cutter widely applicable to aluminum alloy cutting and even cast iron cutting. The high-tech CoroMill 790 endmill structure is not complicated. Its blade axial adjustment is simple and convenient. It also has the advantages of balanced cutting force, wide application field, and precise control of the machining allowance.
Replaceable Head Solid Carbide Tool Solid Carbide cutting tools, especially small diameter tools, are widely used in die cutting of various materials. Between the indexable insert and the solid carbide insert, there is now an alternative third solution that can to some extent cover the characteristics of the first two, which provides both cutting The indexable nature of the edge provides the benefits of using a medium and small diameter solid carbide end mill. Until now, the outlook for the field has been evaluated, pointing out its potential advantages and disadvantages. However, a new tool concept can fully exploit this area.
Although indexable insert technology offers many advantages, modern solid carbide cutting methods with long radial cutting edges and axial feed capability are important, especially when the tool diameter is small. The advantages include high precision, high surface quality, knife performance and light cutting action. The use of indexable insert tools only requires quick and easy replacement of the cutting part of the tool, optimizing the development of this part of the performance, can increase the use of advantages.
The diameter of the indexable insert end mill is as small as 12 mm. Below this diameter, blade installation and clamping become impractical. On the other hand, the diameter of solid carbide end mills can be as small as 1 mm or less. The 10-25mm diameter is a range that both types of end mills have and can be used in a wide range of machining processes. Replaceable head end mills combine indexable inserts with solid carbide, indexable inserts for high-throughput roughing to semi-finishing, solid carbide for semi-finishing to super-finishing Processing. As a third option, the head-removable end mills have the potential for optimization in the cross-application of the two.