This article mainly introduces the development trend of milling, drilling and turning technology in recent years and some new tools developed by some world-renowned tool manufacturers to reflect the current level of metal cutting technology in the world.
Milling technology and tools
There are three main development trends in milling technology: (1) high-speed milling; (2) milling of hard and difficult-to-machine materials; and (3) high-speed milling of hard and difficult-to-machine materials. In order to adapt to the three development trends, the famous tool manufacturing companies of all countries have developed the following advanced tools:
The newly developed HSC-11 milling system from Ceratizit (Columbia, South Carolina, USA) has the following three characteristics: 1 can be processed at a high spindle speed of 56,000 rpm, the resection rate is 3500 cm3 / min; 2 blades are well designed, And micro-scale super finishing; 3 can be used to process a variety of materials, and can be processed under a variety of conditions.
The new carbide milling cutter from Kennametal (Latrobe, Pa.) improves tool life by 30% when machining ferrous materials. KC935M carbide milling cutter is mainly used for dry or wet cutting of steel and ductile iron; KC915M carbide milling cutter is mainly used for light to medium load cutting of gray cast iron and ductile cast iron. Medium temperature CVD (MTCVD) multilayer composite coatings are used on both tool surfaces. In addition, the coating is post-treated to improve the adhesion of the coating, reduce the friction coefficient and improve the coating quality.
Walter Waukesha (Waukesha, Wis.) developed the Xtra tec milling range for end face and step milling, where the F 4033 end mill uses a double-sided square insert with 8 effective cutting edges due to The blade structure is symmetrical and evenly loaded, and is particularly suitable for indexing exchange (cutting edge) in the left and right directions, which is very convenient to use. The F 4042 universal step milling cutter features a large positive rake angle. The large positive rake milling cutter reduces cutting forces, reduces power consumption and reduces surface roughness, making it the best choice for roughing and finishing steel parts and castings.
Several tool companies have recently applied the newly developed advanced plunge-cut milling to the design of new milling cutters to further enhance the machining of milling cutters. Sandvik Coromant's CoroMill 210 milling cutter combines end milling and plunge milling to increase feed speed to 4mm/tooth. In end milling, the amount of removal can be increased to 1400 cm3/min, including the use of plunge milling for deeper and deeper steps. At present, the cutter provides specifications of 25 to 82 mm in diameter.
The newly developed PLX plungers of Iscar Metals (Arlington, TX) feature high efficiency in the ability to easily feed and retract from deeper cavities. In order to avoid the blade from being damaged and scratching the surface of the finished part, the plunge cutter is specially designed with a 45° retraction chamfer. Tool shift programs that are specifically designed to quickly retract the tool (knife) are eliminated. In order to achieve insert roughing, finishing or semi-finishing with a single tool, two specially designed tool cutting edges have been carefully designed.
Stellaram (LaVergne, Tennessee) was also developed at the same time. The company's newly developed 7791 VS plunge cutter has a contour milling productivity that is more than 10 times higher than conventional milling. It is the ideal tool for roughing and semi-finishing of contoured ferrous and non-ferrous materials. The system uses four cutting edge inserts that can cut up to 8 or 11 mm in the radial direction depending on the machined diameter.
The newly developed TuffCut XR carbide end mill from MA Ford (Davenport, Iowa) can be used for roughing and finishing of all materials. The end mills are currently available in 240 sizes, including square shanks, various tool nose radiuses, short, standard, long and extra long slots. The geometry of the flutes is heli-pitch, which reduces the harmonic oscillations produced during machining, allowing for large passes and high cutting speeds. At present, the product has a diameter specification of 1/8" to 1" and 3 to 25 mm, and the coating is AlTiN.
Emuge Corporation (Northborough, Wash.) develops solid carbide end mills for efficient processing of low silicon content (5%) aluminum alloys. Its main feature is that the specially designed tool geometry can greatly reduce the contact area between the chip and the tool, and at the same time make the chip easy to eliminate and reduce the chance of the tool being damaged due to severe wear; the tool surface is coated with TiB2 coating. The company has also developed integrated carbide inserts and milling cutters for efficient processing of high silicon aluminum alloys.
Hole machining technology and tools
The design requirements for the new hole machining tool are to machine holes of different diameters by mounting a plurality of drill bits of different diameters on a common drill body, thereby improving the processing flexibility and eliminating the inventory of various tools in the past. For example, ChamDrill produced by Iscar Corporation is equipped with several drills with a diameter of 1 mm on one drill body for deep hole machining with a length to diameter ratio of 8.
Walter Waukesha has developed the B401X fine-grain carbide drill with replaceable cutting inserts. One cutting insert of the drill bit is fixedly connected by only one screw. The positive rake geometry of the cutting insert and the spiral flutes ensure good chip evacuation and minimal cutting forces. The standard drill has a diameter of 12 to 31 mm and can process a hole with a length to diameter ratio of 7. The extended drill series can process a deep hole with a length to diameter ratio of 10.
Gühring (Brookfield, Wis.) developed the ExclusiveLine drill bit for small diameter holes. The main feature is the machining of the cross section of the oil hole into an elliptical shape, which allows the coolant flow to be twice the circular cross section and improves processing. Reliability and extended tool life. The company has also developed a new cutting edge grinding process that can precisely grind small diameter drills with diameters less than 0.8 mm. In addition, Gühring has developed three new hole machining tool coatings: Super A for difficult-to-machine materials (such as machining titanium alloys, nickel-chromium-iron corrosion-resistant alloys and hardened steels); Iec for dry and minimal lubrication Machining and high-speed cutting; AmoC, high-efficiency processing of amorphous carbon materials for diamond-like properties.
OSG Tap & Die (Glendale Heights, Ill.) has developed a new solid carbide oil hole drill for deep hole machining with a diameter of 2.5 to 20 mm, which can continuously process holes with a length to diameter ratio of 30. Compared with gun drills, it can increase productivity by 15 times. In order to improve the chip removal performance and efficient processing, the fine-grained carbide drill bit is designed as an inverted cone and subjected to TiAIN surface coating treatment.
Turning technology and tools
The development trend of turning tools is to develop high-speed and large-feed tools for machining difficult-to-machine materials such as high hardness and high toughness.
Kennametal's KB9640 is an integral CBN turning tool with a surface coated with a multilayer of alumina by a CVD process. The multi-layered alumina coating coated on the tool surface has good resistance to brittle fracture and excellent resistance to chemical and abrasive wear, and it is more suitable for larger depth of cut in combination with the tough CBN tool bottom layer. High reliability and efficient processing. Its main purpose is to carry out high-power roughing and finishing of pearlite gray cast iron and roughing of hardened steel, chilled cast iron and hard-plated materials.
The company has also developed several new carbide tools for high-volume processing of materials used in aerospace, aerospace, medical device and food manufacturing. The KC5510 and KC5525 tools are made of hard alloy with nanostructures and coated with a high-performance TiAlN coating for high-power cutting and long tool life at high cutting speeds. life. In addition, the well-designed chip breaker geometry provides very high cutting stability and excellent surface finish.
High-speed machining of cast iron is possible with the newly developed CA4010 carbide tool from Kyocera Industrial Ceramics. The main feature of the tool is the surface coating of a multi-layer composite coating, in which the surface layer is a TiN coating resistant to oxidation; the middle is a thick micro-crystalline Al2O3 film, which can further prevent oxidation of the tool surface at high cutting speed. The bottom layer is a TiCN coating that resists tool breakage and microcracking. In addition, the new ZS-type chipbreaker geometry improves blade cutting stability and cutting edge strength for intermittent and heavy-duty cutting and reduces vibration during machining.
The patented Xcel tool is manufactured by Sandvik. Its main structural feature is the selection of an 80° insert that provides high speed machining and is more suitable for semi-roughing superalloys and titanium alloys than diamond inserts. The 80° insert, like the square insert, can be machined with a 45° plunging angle for easy programming and reduced tool wear. The tool also has the ability to machine the corners of complex-shaped parts, provide excellent plunge in limited space, and can be machined in both directions. Compared to a round insert, it reduces radial forces and keeps the chip thickness constant.
Seco-Carboloy's newly developed TP3000 is used for part turning with large dimensional changes, which enables intermittent cutting and high-speed feed machining of large parts in small batches or large batches.
Iscar's newly developed HeliTurn system is designed for efficient turning operations and is characterized by the ability to clamp helical cutting edge inserts in a tangential direction. When cutting steel, it can reach a depth of 8mm and a large amount of cutting (about 1.2mm / r). The four helical cutting edges of the insert ensure a positive radial rake angle, resulting in less cutting forces and improved tool life and machining accuracy.
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