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1. Responding to the needs of users in the industry, leading companies to push new products
For example, Guhring of Germany has introduced a set of tools for machining aluminum cylinder heads (including face milling cutters, conduit hole valve seat compound boring tools, stepped hole boring tools, solid carbide straight groove drills, step drills, boring drills, etc.); Toshiba, Japan The company's high-efficiency ceramic milling cutters, diamond milling cutters (milling speeds up to 4000m/min) and carbide machining tools; Sandvik introduces CoroPak08.1 new generation of high-efficiency tools (covering areas such as milling, turning and drilling), such as CoroMill490 Square shoulder milling cutters can produce finished products in one pass (maximum depth of up to 5.5mm), can also be used for contouring edge cutting, and even for slot milling.
Also, Iscar's new research and development of SUMO series of cutting tools, such as mold processing can replace high-speed steel (HSS) end mills, solid carbide end mills, transformers, end mills, suitable for milling deep cavity (cut depth up to 8mm) hot wheel milling cutter, high feed rate dense tooth milling cutter (with mini butterfly blade), efficient milling of UPGRADE milling cutter, simultaneous roughing and machining of wave edge milling cutter; Hitachi The company newly developed ASR multi-blade high-feed arc angle milling cutter, which can perform small depth-depth and high-feed machining on the mold cavity, and milling with Φ32mm-5-blade arc angle milling cutter (using JX1045 super-lubricated coating blade) For 40CrMnMo7 steel, the cutting amount is: milling speed 300m/min (speed 3000r/min), feed rate is 2.5 times of the past 2 blade milling cutter, up to 50m/min, feed per tooth 3.3mm/z, depth of cut 0.3mm.
The new grade TP3500 for the high cutting of the mountain has been introduced recently, which has further enriched the company's DuratomicTM grade series for ISOP applications (steel turning). The TP3500's good toughness meets the needs of more customers, and its toughness level is also suitable for ISOM applications (stainless steel turning).
The TP3500's various processes (from finishing to heavy-duty interrupted cutting) deliver the same high performance. Regardless of rough machining, rough turning, small part turning and stainless steel turning, the new DuratomicTP3500 grade and toughness ensure high processing efficiency even under harsh conditions. The TP3500 is reliable, versatile, and dry and wet. Therefore, it is an ideal choice for mixed production.
It is worth mentioning that in order to meet the growing demand of other industries in the automotive industry, the WIDIA company of the Kennametal Group has developed a series of high-efficiency cutting tools. In terms of machining the crankshaft, it has various high-efficiency special tools such as crankshaft internal milling, crankshaft high-speed outer milling, car pulling, and car pulling. If a multi-row car pull tool is used, a crankshaft can be machined in 32 seconds. It is said that more than 1,800 users in the world use WIDIA special tools for crankshaft production.
In recent years, Kennametal Corporation of the United States has introduced the SPF bit Harvi IITM series of end mills, which are favored by users. The former is suitable for processing aerospace industry carbon fiber reinforced polymer matrix composites (CFRP), which use a large number of wings, fuselage, Rear wing, propulsion and other devices.
SPF drill tip has a special geometry, which makes the drill centering good and the cutting edge is very sharp, avoiding the phenomenon that the layered fiber can not be cut during drilling; the drill base material is solid carbide, and the surface is multi-layer smooth CVD diamond coating Layer, so it has high wear resistance, good chip removal performance, and the service life of the drill can reach more than 2 times that of ordinary PCD (polycrystalline diamond).
HarviIITM series end mills are used for machining special tools such as stainless steel, titanium alloy and nickel-based alloy. They are characterized by 5-blade, 38° large helix angle, rounded corners, asymmetric design between blades, and the shape of the blade section. Parabolic, AlTiN (MT) coating, can adapt to high efficiency processing.
At the same time, some very versatile, economical and efficient tools have become the leading manufacturers to push new products with their competitive advantages. The mountain is higher than the new DoubleOctomill double-faced face milling cutter in October this year. It is suitable for both rough and finishing.
This double octagonal face milling cutter uses a positive rake insert with 16 cutting edges. The blade seat features an innovative design HSS locating pin that eliminates the need for a tool setting to achieve a very low level of disk jerk, and the high-hardness HSS locating pin (HRC65) ensures an extremely long life of the blade holder. The overhaul blade (2mm) and the extremely high precision combined with the new blade design make the axial runout optimal, so this new double octahedron cutter helps users to further shorten the production cycle and save costs.
The DoubleOctomill double-faced milling cutter hard coating (HV700) not only reflects the high quality of the tool, it also protects the tool from wear and prevents the chip from being welded to the body. The series currently has three different pitches – normal pitch and sparse teeth – to provide optimum productivity for different machine materials. Different blade locking solutions for different pitches make machining operations easier and safer.
2. Multi-function tools and special structural tools are available
The use of CNC machine tools flexible multi-tools to develop a combination of processing a significant feature of current cutting.
Japan's Mitsubishi Corporation develops OCTACOT multi-function milling cutters that can be equipped with octagonal or round inserts to complete milling, groove, step, chamfering, contouring and beveling.
In addition, special structural tools such as heat pipe tools with high-pressure internal cooling channel cutters can be used to reduce the temperature in the cutting zone and improve tool life.
The heat pipe type cutter and the heat pipe type face milling cutter also have their own characteristics. The structure is basically the same as that of the ordinary outer turning tool carbide face milling cutter, and the heat pipe is made inside the single cutter tooth or the milling cutter.
Heat pipe cutter A self-cooling tool that can greatly reduce the cutting temperature (the thermal conductivity of the heat pipe is several hundred times higher than that of silver and copper rods), which improves the cooling effect, so there is no need to cast the cutting fluid from the outside, especially for CNC machine tools. , processing heart automatic production line applications.
Tool cooling channel design is also an important issue in high speed machining tool design. Due to the large amount of heat generated during high-speed machining and the limited heat resistance of the tool material, high-pressure coolant is used and transported to the cutting zone through the tool supply (oil) channel to cool the cutting part of the lubrication tool, improving tool life and reliability. way. In recent years, in-band cooling liquid supply (oil) passage tools have been extended from deep hole machining tools to ordinary shallow hole drills and reamers end mills.
For example, Seco Tool Company has introduced a replaceable carbide head bit (there are three types of drill heads: P-type head for cutting steel, K-type for cutting cast iron and aluminum, M-type for high-strength steel Corrosive steel). Japan uses TiN-coated carbide single-edge reamer (cutting speeds of up to 150-400 m/min), which have internal cooling supply holes and are getting smaller and smaller. According to reports, Mitsubishi Corporation of Japan uses a special process to make a small drill with an oil hole MZS carbide, which can be as small as 3-4.5mm in diameter and 0.4-0.6mm in oil hole diameter. This cooling method is currently used even if the cutting conditions are poor to cut the knife. The liquid supply method can be realized by the machine spindle or the tool holder.
Tool clamping requirements
Under high-speed machining conditions, the interface structure between the tool and the machine tool is very important, the tool clamping should be firm, the tool system should have sufficient overall rigidity, and the cutting head must be able to change quickly. In addition to the general cutting requirements (such as force torque transmission), the rotary tool clamping structure should also have high positioning accuracy and low rigidity.
Therefore, for linear motion tools, a lever-type upper pressure type combined with a high-rigidity clamping mechanism is required. For the rotary shank tool, the traditional tool clamping method such as the spring collet screw cannot be used, and the high-precision hydraulic chuck (such as the German developed 1:10 short cone hollow taper shank automatic quick change chuck) and the heat shrink chuck are required. Triangular static pressure chuck, built-in dynamic balance mechanism handle, torque monitoring chuck and other new products. At present, various chucks have become a professional tool factory to produce high-speed cutting tool accessory products.
For example, Sandvik CoroGrip chuck, Japan NT company heat shrink chuck (for speed up to 70,000r / min) "zero jump chuck" (tool radial round jump ≤ 2cm), and CV-G milling cutter chuck (maximum speed Up to 30000r/min) can be supplied with the tool.
The inner hole of the chuck is triangular in shape, and the diameter of the inscribed circle of the triangular edge is smaller than the diameter of the shank to be clamped, and an external force is applied to the chuck by a hydraulic urging device to deform the chuck, and the inner hole becomes The hole has a hole diameter slightly larger than the diameter of the shank. At this time, the shank is inserted, and then the external force is removed, and the inner hole is re-contracted into a triangular shape, and the shank is clamped at three points. The chuck is compact, symmetrical and has high precision. Compared with the heat shrink chuck, the tool is easy to handle and disassemble, and the urging device is simpler than the heating and cooling device.
In order to ensure the reliability of machining accuracy during high-speed precision cutting, the tool must be advanced and balanced before being clamped to the machine tool spindle to ensure the safety of the machining system. Epb has introduced a tool holder with a built-in dynamic balance mechanism tool that can move the internal counterweight by rotating the compensation ring to compensate for the unbalance of the tool, while the scale on the compensation ring indicates the amount of adjustment.
Hardware tools industry set off to develop new tool boom
In recent years, the hardware tool industry has developed various new types of tools for the automobile, motorcycle, high-speed train, aerospace mold and other industries. It has the characteristics of high efficiency or innovative technology and plays an important role in promoting the advancement of processing technology in these industries.