The key technology of high-speed milling technolog

2022-08-19
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With the continuous development of computer technology, information technology, automation technology and tool material technology, high-speed machining technology has also developed rapidly. High speed machining technology includes high-speed turning, high-speed milling, high-speed grinding and high-speed drilling, among which high-speed milling technology is the most widely used, and its application fields include aerospace, automobile, mold and other manufacturing industries

problems of traditional EDM molds

1) EDM is a "micro cutting" machining process based on discharge ablation, with slow process and low production efficiency

2) in the process of discharge ablation, the mechanical properties of the workpiece surface are damaged to a certain extent, and micro cracks will be produced

3 Shandong Branch of the Institute of materials will help Shandong Huayu embark on a new journey of alloying transformation and upgrading in terms of platform construction, scientific research and development, project application, market research, talent training, etc.) the surface roughness after EDM cannot meet the requirements of mold cavity, and the BASF thermoplastic ultrason E has excellent heat resistance, product quality is difficult to guarantee, and production cycle is long

advantages of using high-speed milling technology to process molds

the production cycle of molds is closely related to the economic benefits of mold enterprises. In mold production, not only the pursuit of precision and surface roughness, but also the production cycle is particularly important. High speed milling has become an important choice of modern mold processing technology because of its high efficiency, high precision and high surface quality. The advantages of using high-speed milling to process molds mainly include the following points:

1) process reduction. Generally, no subsequent processing is required, and the cost is low, which reduces the relevant costs of these processes

2) the production efficiency is significantly improved. Due to the extremely high cutting speed, the cavity machining process is several times faster than EDM, saving more than 50% of the time. One time clamping of the workpiece can complete the rough and finish machining of the cavity and the machining of other parts of the mold, and it is easy to realize the automation of the machining process

3) good product quality, high machining accuracy, and easy to ensure surface quality. The chip is cut off instantly, and the residual stress on the workpiece surface is small; 95% cutting heat is taken away by chips, and the thermal deformation of the workpiece is small; High excitation frequency, small workpiece surface roughness (≤ ra0.6 μ m) , high-speed milling can be used instead of grinding

4) can process hard parts and thin-walled parts. High speed milling can directly process hardened steel, and the hardness of steel can reach about HRC62; The transverse cutting force is small, so it can process thin-walled parts

5) mold correction or modification can be completed quickly through cad/cam, and there is no need to prepare a new electrode or a new mold

key technology of mold high-speed milling

1) tool system

tool system refers to the system structure of the tool, which mainly refers to tool material, tool structure and tool handle. Tool materials have high hardness and wear resistance, good strength and toughness, good heat resistance and processability. At present, the tool materials used in high-speed milling mainly include diamond, cubic nitriding shed, ceramic tools, cemented carbide tools and coated tools

the tool structure is mainly composed of integral and inserted teeth. The gear insert tool mainly adopts the machine clamp mechanism. Due to the centrifugal force of the high-speed milling tool, the clamping mechanism will be damaged and the blade will be thrown away. Therefore, the tool body clamping mechanism must have high strength, fracture toughness and stiffness to ensure safety and reliability

the tool holder system mainly solves the problems of insufficient rigidity, unstable repetition accuracy, the influence of centrifugal force, and inconvenient tool change of tool holder in high-speed milling

2) machine tool system

machine tool system refers to the structural guarantee system to realize high-speed milling elements, mainly the high-speed spindle system to ensure the high-speed cutting speed. 1) the friction resistance system of the host part and the rapid feed system to obtain the accurate feed speed

high speed spindle system is one of the keys of high speed milling. The high-speed spindle system should have enough rigidity and high rotation accuracy, and the temperature tends to rise after reaching a fixed value of 1; Light weight, compact structure and small inertia; Good thermal stability; Low vibration and noise; Good cooling and lubrication system

3) mold cad/cae/cam software system

model building (CAD), analysis (CAE) and manufacturing (CAM) process software systems must be able to accept and process data from other systems, so they must have consistent and standardized interfaces. At present, IGES (original graphics exchange standard) is the most commonly used interface standard for mold processing. The key of high-speed milling is that the programmer used in cad/cam can automatically adjust the best machining method of milling machine tools

4) CNC control system

the safety CNC control system should have fast data processing ability and high functionality to ensure good machining performance during high-speed cutting. The requirements of CNC control system for high-speed milling die are as follows: (1) excellent feed control function; (2) The cycle time of program section is short; (3) High interpolation accuracy. In order to ensure the interpolation accuracy at high speed, it is necessary to have the functions of feedforward and preprocessing a large number of advanced program segments. In addition, contour control technologies such as non-uniform rational B-spline interpolation, recoil acceleration, smooth interpolation, bell acceleration, etc. can also be used; (4) Interface data processing network. In order to shorten the data processing time, the CNC controller must be able to directly transmit the program through "Ethernet"

At present, high-speed milling technology has been widely used in mold manufacturing industry for its high efficiency, high precision and high surface processing quality. With the continuous development of cutting tool technology, machine tool technology, software technology, numerical control technology and other related technologies, high-speed milling technology will become increasingly perfect and play an increasingly important role in modern manufacturing industry

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