Production of the hottest non-standard cutting too

The manufacture of non-standard tools

in the process of machining, we often encounter some situations that are difficult to process with standard tools. Therefore, the manufacture of non-standard tools is very important for mechanical cutting. Because the use of non-standard tools in metal cutting is often seen in milling, the production of non-standard tools in milling is briefly introduced

because the production of standard tools is aimed at the cutting of a wide range of common metal parts or non-metal parts, when the workpiece is overheated and the hardness increases, or the workpiece is stainless steel, it is very easy to stick the tool, and there are also some workpieces with complex surface geometry, or the machined surface has high roughness requirements, the standard tools cannot meet the needs of processing. Therefore, in the processing process, it is necessary to carry out targeted design on the material, geometric shape and geometric angle of the tool, which can be divided into two categories: no need for special customization and special customization. Tools that do not need to be customized mainly solve two problems, such as size and surface roughness

if it is a size problem, you can choose a standard tool with a size similar to the required size, which can be solved by changing the grinding, but you also need to pay attention to two points:

1) the size difference should not be too large, generally not more than 2mm, because if the size difference is too large, it will cause the groove shape of the tool to change, directly affecting the chip space and geometric angle

2) if the milling cutter with edge hole is used to drive the cement and glass industry to fully implement the sewage discharge permit, it can be changed to grinding on ordinary machine tools with low cost. If the keyway milling cutter without edge hole cannot be carried out on ordinary machine tools, it needs to be changed to grinding on special five axis linkage machine tools, and its cost will be higher

if it is a surface roughness problem, it can be achieved by changing the geometric angle of the blade. For example, increasing the degree of the front and rear angles will significantly improve the surface roughness of the workpiece. However, if the machine tool of the user is not rigid enough, the blunt cutting edge may improve the surface roughness instead. This aspect is very complex, and it is necessary to analyze the processing site before reaching a conclusion

the tools that need to be specially customized are mainly used to solve the following problems for the activities of launching machines, buying machines, sending them for debugging, or sending freight

1) the workpiece to be processed has special shape requirements, such as lengthening the cutting tool required for processing, adding the end tooth reverse R, or having special cone angle requirements, handle structure requirements, blade length dimension control, etc. If the shape requirements of this kind of tools are not very complex, it is actually easy to solve. The only thing to pay attention to is that the processing of non-standard tools is relatively difficult. Therefore, users should not excessively pursue high precision when they can meet the processing requirements. Because high precision itself means high cost and high risk, which will cause unnecessary waste to the production capacity and cost of the manufacturer

2) the workpiece to be processed has special strength and hardness. For example, if the workpiece is overheated, the strength and hardness are high, and the general tool material cannot be cut, or the tool sticking is severe. Therefore, it is necessary to put forward special requirements for the tool material. The general solution is to choose high-grade tool materials, such as high-speed rigid tools containing cobalt, which have high hardness to cut the hardened and tempered workpiece materials, and high-quality cemented carbide tools can be used to process high-hard materials, or even milling instead of grinding. Of course, there are also some special cases. For example, when processing aluminum parts, a kind of tool called superhard tool in the market is not necessarily suitable. Although aluminum parts are generally soft and can be said to be an easy to process product, the material used by superhard tool is actually an aluminum high-speed steel, which is indeed harder than ordinary high-speed steel, but it will cause the affinity between aluminum elements when processing aluminum parts, Instead, the tool will aggravate the wear. At this time, if you want to get high efficiency, you can choose cobalt high-speed steel instead

3) the processed workpiece has special cumulative requirements for chip holding and chip removal in more than 400 new material industry standards. At this time, less teeth and deeper chip holding grooves should be selected, but this design can only be used for materials that are relatively easy to process, such as aluminum alloy

there are many problems that need to be paid attention to in the processing design and processing process of non-standard tools:

1) the geometric shape of the tool is relatively complex. During heat treatment, the tool is prone to bending, deformation, or local stress concentration. Therefore, attention should be paid to avoiding the parts prone to stress concentration in the design. For the parts with large diameter changes, bevel transition or step design should be added. For slender parts with large length diameter ratio, it is necessary to check and straighten them every time they are quenched and tempered during heat treatment to control their deformation and runout

2) the material of the tool is relatively brittle, especially cemented carbide, which makes the tool break once there is a large vibration or a large machining torque in the processing, which often does not cause great damage in the processing with conventional tools, because the tool can be replaced when it is broken, but in the processing with non-standard tools, the possibility of replacement is small, so once the tool breaks, It will cause a series of problems, such as delivery delay, which will cause great losses to the user

all the above are for the tool itself. In fact, the manufacturing of non-standard tools is by no means so simple. This is a systematic project. The experience of the design department of the manufacturer and the understanding of the processing status of the user will affect the design and production of non-standard tools. The processing and testing methods of the production department of the manufacturer will affect the accuracy and geometric angle of non-standard tools. The repeated return visits and collection of materials and information by the Sales Department of the manufacturer will also affect the improvement of non-standard tools, which will play a decisive role in the success of the user in using non-standard tools

in a word, 4 non-standard tools with different legal efficiency are a special tool produced in response to special requirements. Choosing an experienced manufacturer will save users a lot of time and energy. (end)