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The development of tool materials and coating technology provides technical support for improving processing efficiency and reducing manufacturing costs. For example, according to a document provided by Kennametal, the use of KC9110 material for cutting steel parts may be very helpful for machining efficiency: KC9110's medium temperature CVD and ordinary CVD coatings have a total thickness of 24μm, of which α phase The alumina structure is stable and the performance is superior, and the TiCN formed by the medium temperature CVD greatly eliminates the weak η phase between the cemented carbide substrate and the aluminum oxide film layer, thereby improving the bonding ability of the film layer, thereby greatly improving the cutting. Speed; the cobalt-reinforced cemented carbide substrate enhances the edge toughness of the tool to increase the feed rate; its edge is also polished after coating, reducing the gap between the chip and the blade. Friction reduces the occurrence of bond wear and improves tool life. In the actual processing of a certain company in the United States, due to the simultaneous increase in cutting speed and feed rate, the processing cost of this process has been reduced from nearly $37,000 to less than $9 million, a decrease of more than 75%.
Another example is the whisker toughened ceramic material of Kennametal Metals under the trade name "赛龙". The main components of this ceramic tool material are Al2O3 and ZrO2, and toughened with SiC whiskers having an aspect ratio of 20 to 200 times. This kind of whisker can effectively pinch and resist when the ceramic tool is subjected to torque load and crack propagation, and can also play a uniform load when the load is concentrated. In the high-temperature milling of the Boeing 777 engine mount, the nickel-base alloy with a hardness of 28HRC has a cutting speed of 1310m/min and a feed rate of 2000mm/min, helping the company to reduce the processing cycle from 45 hours to 14 hours. , which greatly improves the processing efficiency.
The grain size of the tool material has a large effect on the tool performance. When milling the hardened material of 62HRC, the tool wear of the fine-grained cemented carbide KC635M for 25min is equivalent to that of the ultra-fine grained cemented carbide KC637M for 70min, indicating that in the processing of hard materials, the ultra-fine particle cemented carbide KC637M The wear resistance is nearly three times higher than that of fine particle cemented carbide KC635M.
Paying attention to the dynamic balance of the tool when high speed is required is one of the conditions to ensure that the tool can be machined at the normal cutting speed. If there is an imbalance, when the speed is doubled, the centrifugal force will increase by 4 times, which will force us to reduce the speed and reduce the efficiency. Therefore, attention should be paid to the dynamic balance of the tool at high speeds.
2. Increase the feed rate
The use of the wiper technology for large feed machining not only improves machining efficiency, but also reduces total manufacturing costs.
Large feed milling has been around for a long time, and the large feed type of turning is a new technology that has been promoted by leading tool suppliers in the world in recent years. This technique is commonly referred to as the "Wiper" technique, which uses a short straight line or a short large radius arc to join the corner fill and minor cutting edges to reduce the roughness of the machined surface. The use of this technology can greatly reduce the surface roughness of the workpiece and improve the surface quality while maintaining the original production cycle; it can also greatly reduce the processing time and improve the processing efficiency while maintaining the original workpiece quality. If the same feed rate of f = 0.63 is used, the surface roughness of the workpiece machined by R0.8 ordinary blade is about 16 μm, while the surface roughness of the workpiece machined with Wiper blade (MW groove) is only 2.5 μm, if R0 is used. 8 ordinary blade to achieve 2.5μm workpiece surface roughness, the feed rate needs to be reduced to about f = 0.22.
The use of Wiper technology allows higher cutting parameters to be used while maintaining the same surface quality, which means increased productivity. Then, the Wiper technology blade offers another possibility of achieving better surface quality at the same feed rate. If we originally needed semi-finishing, it might not be necessary due to the use of Wiper technology. This is the problem of reducing the number of processing steps that we will discuss later.
The so-called "high-performance machining" that is currently being implemented internationally is a typical example of the use of large feeds in milling. Many internationally renowned tool manufacturers offer such tools. This type of tool generally uses a small lead angle to reduce the influence of radial cutting force on tool deformation, so that very large feed can be used for actual machining to improve cutting efficiency.
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