1. Summary
In the modern manufacturing industry, we are looking at how to further improve the quality of the product, shorten the manufacturing cycle, reduce production costs and improve production efficiency.
In the cutting industry, there are ways to improve the processing efficiency by advancing how to deal with difficult materials, how to save processing time and so on, and how to improve the processing efficiency of roughing is the most efficient way to improve the processing efficiency. Now, in order to realize the large chip discharge amount, the machine-clip type high feed tool which increases the angle of the outer peripheral cutting edge is widely popular, and on the other hand, from the viewpoint that the actual R angle can be cut, it is possible to easily manage the machining allowance In the past, there are still many places in the use of round blade cutter, which has been widely used in the round blade tool, and now significantly improve its processing efficiency and tool life.
This article will introduce both the sharpness, strength and strength, and can improve the productivity of the round blade holder cutter 'double-sided rotary die' (Figure 1) features, cutting performance and processing examples.
2. Features of double-sided swivel
2.1. Features of the blade
Two-sided rotary die, using a single-sided use of four cutting edges, double-sided can use a total of 8 blade edge, to help users reduce their operating costs. (Figure 2) while the blade peripheral cutting edge is unique Spiral blade design, therefore, both sharpness, and edge strength, to achieve a stable high efficiency roughing.
2.2. The clamping mechanism of the blade
In the conventional round blade clamping method, the irregular cutting load fluctuates from the use of the R-shaped portion on the outer peripheral side of the blade, and the blade is followed by the channeling, resulting in a shorter life of the tool.
Therefore, in order to improve the fastening effect of the blade, the double-sided rotary blade has a unique anti-channeling mechanism for setting the restraint plane on the outer side, , Can be firmly attached to the blade (Figure 3), so that the outer edge of the blade and the knife blade surface close fit, in use not only to prevent the blade shift, and can prevent the blade up channel position, to achieve stable high efficiency roughing The
2.3. Excellent thermal shock resistance of the new PVD material 'JC7560P'
In the rough milling of the face milling, the problem of shortening the life of the tool is common due to the thermal cracking caused by the heat of the cutting and the impact, which causes the chipping of the tool to become shorter and the chipping caused by the thermal cracking, even if it is a very small chipping , Will increase the resistance when cutting, and exposure tool base, to speed up the tool wear.
(Figure 4) This material uses a heat-resistant cracking and resistance to chipping the excellent carbide substrate, and the newly developed research and development of the PVD coating material 'JC7560P' (Figure 4) The new coating, which is made of a wear-resistant film, a low coefficient of friction and excellent resistance to oxidation, is used to laminate the laminate between the substrate and the coating The control of good heat-resistant cracking, resistance to chipping, wear resistance balance, to achieve stable long-life processing at the same time, the coating surface for the golden hue, easier to identify the blade of each blade use and wear Happening.
From the characteristics of the material can be seen above, double-sided rotary die can be used for HRC35 below the hard material of high efficiency, long life processing.
2.4. The characteristics of the knife body
The 'G-BODY' of the surface of the 'G-BODY' has a high surface hardness of HRC65 or higher, with high hardness, strong heat resistance and strong High rigidity, blade durability and blade life than traditional products increased by 30% or more, in the brutal processing environment can also play its power. And also has anti-chip adhesion and anti-rust effect.
In addition, the use of both sides of the face milling in the rough, the chip removal is generally more difficult than the traditional single-use type blade, and double-sided rotary die with the best chip groove shape design to ensure its Chip performance.
3. Double-sided rotary die cutting performance
3.1. Cutting resistance evaluation
(Figure 5) is the processing of carbon steel (S50C) cutting resistance evaluation results. Processing machine using the BT50 vertical machining center.
Cutter type: EXTDM-5050R-12-22 (φ50 × 5N)
Blade Model: RNMU1205MOE-MM
Blade material: JC7560P
Processing parameters: VC = 180m / min, fz = 0.6mm / edge, Ap = 1mm, ae = 30mm, along the milling, air-cooled, only one blade processing.
Compared with the cutting resistance of the traditional products (single-sided use round blade), the double-sided use type blade has the advantages of increasing the geometric shape of the blade compared with the single-use type blade. But the double-sided rotary die as described above, due to the use of a unique spiral cutting edge shape, effectively reducing the cutting resistance, with the same single-sided use of the same type of blade Cutting force.
3.2. Tool life evaluation
(Fig. 6) is the result of machining the tool life of the machined stainless steel (SUS420J2).
The machine is using the BT50 machining center.
Cutter type: EXTDM-5050R-12-22
Blade Model: RNMU1205MOE-MM
Blade material: JC7560P
Processing parameters: VC = 260m / min, fz = 0.3mm / edge, Ap = 0.5-2.5mm (including 1 ° tilt cut into the processing), ae = 30mm, along the milling, air-cooled, only one blade processing.
(Double-sided use of the blade) compared to the processing life. J company's products processing length 10m, L company's products processing length 25m, cutting edge of the company's traditional products (single-use round blade), other companies the same product (double-use blade) The face of the chipping, can no longer continue to use, while the double-sided rotary die length of up to 40m, still belong to the normal wear and tear.In addition, the double-sided mold with the company's traditional products (single-sided use round blade) Equivalent, and double-sided rotary blade can be double-sided use, the length of each piece of blade processing is single-sided use of the blade 2 times, in order to achieve the reduction of tool costs to improve the production efficiency of the scene.
4. Example of processing of double-sided swivel
(EXTDM-5050R-12-22, φ50 × 5N) to improve the processing efficiency and tool life of the processing example is a problem in the known Processing of the INVAR material processing, double-sided rotary mode compared with the traditional products, processing efficiency increased by about 1.2 times the tool life extension of 1.3 times the processing example. Double-sided rotary die due to the use of cutting resistance can be achieved to reduce the blade shape And improve the performance of the new chipping resistance of the new material, the blade did not occur chipping phenomenon, the processing process is stable, the blade is a normal wear and tear.Therefore, can be stable use of all the edge, multi-edge design to achieve the tool to reduce the cost of small The contribution.
5. Summary
This paper describes the characteristics and performance of the double-side rotary die, which is a high-efficiency machining machine. This paper describes the processing examples centered on the processing of difficult materials, but the 'double-sided rotary mode' Hard steel can be easily handled.Using 'double-sided rotary mode' can increase the amount of chips per unit time, effectively reduce manufacturing costs.
In the future, Dai Jie will continue to integrate with the user, to provide users with the needs of users of new products, new processing technology! Your company in the process of cutting, we are in the pursuit of increased production efficiency, further reduce manufacturing costs. Sure, it's my motivation!