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In the past, high-speed cutting focused on high spindle speeds ranging from 8,000 to 100,000 rpm. Many applications were experimentally driven by machine tools and the aerospace industry, and early high-speed cutting used 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 a new thing. It has been in many industries such as mold manufacturing for decades. As a process, it used to be seen as a small tool for high-spindle speed machines. However, today, high-speed cutting has a wider range of applications. In the 1990s, the development of high-speed cutting focused on the overall concept, including the creation of machine tools with a spindle speed of 200,000 rpm. High spindle speeds and high feed rates are highly valued. Research institutes have shown that high speeds can have serious consequences and high risks when tool or machine tool 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 demonstrate the importance of optimizing high-speed cutting factors for successful high-speed cutting.
Thanks to the research and development of machine tool builders, software developers, cutting tool manufacturers and research institutes, high-speed cutting (HSM) now has a wider application space. Most importantly, the actual process of high-speed cutting has not only stayed in theory, but has been applied to all aspects of the shop. 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, is as effective as the machining capabilities of machine tools, software, and cutting tools. In many years of practical applications, the development of tools in high-speed cutting has moved toward higher performance. Milling is an important part of the high-speed cutting process, and its innovations have affected the performance of milling cutters in many tooling applications. In high-speed cutting, speed is a keyword that represents the spindle speed, cutting speed or feed rate. High-speed cutting can be achieved by optimizing the milling process with high cutting speed or high feed rate.
New developments in aluminum die milling
When it comes to high-speed cutting and indexable tools, safe blade fixing is a top priority. Increasingly high milling machine spindle speeds and table feeds (especially when performing aluminum cutting) result in high centrifugal forces and the resulting large load on the blade mounting components. The finite element method for analyzing load distribution is particularly valuable when developing satisfactory solutions and finding working models for indexable tools for high-speed cutting faster, and it can be used to design optimal cooling. The liquid channel and outlet structure help the chip evacuation in an optimal way. This has resulted in a new generation of high speed cutting tools for aluminum alloy cutting.
The CoroMill790 indexable end mill is an example of a tool for machining aluminum alloys at high speeds. This type of end mill is mainly used in high-speed machining processes such as cavity cutting, edge cutting, slot milling, and profiling in mold manufacturing. The fixing of the insert is achieved by a specially developed insert-knife interface. The serrated contact surface of the insert groove bottom and the back of the insert not only maximizes the safety in high-speed milling, but also ensures machining accuracy. The blade is evenly stressed, making the processing smoother and safer, and prolonging the tool life. The above design greatly enhances the cutting quality and improves the processing capacity.
The CoroMill790 end mill serrated contact surface design can also be widely used in face milling cutters used in aluminum machining, especially cast aluminum parts such as molds, engine blocks, gearbox housings, etc. From semi-finishing to super-finishing, the cutting speed is increased to 8000m/min. The positive rake angle of the CoroMill790 end mill can be made of cemented carbide, polycrystalline diamond (PCD) or cubic boron nitride (CBN). This design makes the milling cutter widely suitable for aluminum alloy cutting and even cast iron cutting. The high-tech CoroMill790 end mill structure is not complicated, its blade axial adjustment is simple and convenient, and it also has the advantages of cutting force balance, wide application field and precise machining allowance.
Interchangeable solid carbide tool
Solid carbide cutting tools, especially small diameter tools, are widely used for die cutting of various materials. Between the indexable insert and the solid carbide tool, there is now an alternative third solution that can cover the characteristics of the first two to some extent, and it provides both cutting The indexable nature of the blade provides the benefit of using a medium to small diameter solid carbide end mill. Up to now, the prospects for this field have 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 benefits, modern solid carbide cutting with long radial cutting edges and axial feed capability is important, especially when the tool diameter is small. Advantages include high precision, high surface quality, knife performance and light cutting. The use of indexable insert tools requires a quick and easy replacement of the cutting portion of the tool, optimizing the performance of this part of the tool and increasing the use advantage.
The indexable insert end mill has a diameter as small as 12 mm. Below this diameter, the mounting and clamping of the insert becomes impractical. On the other hand, the diameter of the solid carbide end mill can be as small as 1 mm or less. The diameter of 10-25mm is the range of both types of end mills and can be widely used in many machining processes. The interchangeable end mill combines the indexable insert with the solid carbide. The indexable insert can be used for high-efficiency roughing to semi-finishing, and solid carbide for semi-finishing to superfinishing. machining. As a third option, the head-removable end mill has the potential to be optimized in the cross-application area of ​​the two.
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