Common Problems and Solutions of Superhard Tool Solutions

Release time:

2022-05-07

Superhard tool solutions in deep hole processing, often appear workpiece size accuracy, surface quality, tool life and other issues, how to reduce or avoid the occurrence of these problems, is our current urgent problem to be solved, then, the following together to understand the common problems and solutions of superhard tool solutions!

　　Superhard Tool SolutionsIn deep hole machining, there are often problems such as workpiece size accuracy, surface quality, tool life, etc. How to reduce or avoid the occurrence of these problems is an urgent problem for us to solve at present. Then, let's learn about the common problems and solutions of superhard tool solutions!

1. Superhard tool solutions have problems with larger apertures and larger errors.

1) Cause of occurrence

The design value of the reamer outer diameter is large or the reamer blade has burrs; chip nodules are attached to the reamer blade; the runout difference of the reamer tip during sharpening is very poor; when installing the reamer with improper selection of cutting fluid, the surface of the taper shank is not cleaned up or the cone has scratches; The cutting speed is too high; The feed is not appropriate or the machining allowance is too large; The reaming hole is bent with too large main deflection; after the flat tail of the taper shank is installed on the spindle of the machine tool, the taper shank cone interferes; the spindle is bent or the spindle bearing is loose or damaged; the reamer is not loose well; when the hole is opened with a different shaft or hand from the workpiece, the force of the hands is uneven, The reamer swings left and right.

2) The solution

According to the situation, reduce the outer diameter of the reamer; reduce the cutting speed; carefully trim with oil stone until it is qualified; select the cutting fluid with good cooling performance that controls the swing difference within the allowable range. Before installing the reamer, wipe the oil stains inside the reamer taper shank and the machine tool spindle taper hole, adjust the feed appropriately, or straighten or discard the curved reamer that reduces the machining allowance and the main deflection angle appropriately. Re-adjust the floating chuck; grind the flat tail of the reamer; adjust or replace the spindle bearing; adjust the coaxiality; pay attention to correct operation.

　　2 .Superhard Tool SolutionsProblem: aperture reduction

1) Cause of occurrence

The design value of the reamer outer diameter is small; Elastic recovery reduces the aperture; When reaming, if the margin is too large or the reamer is not sharp, elastic recovery is easy to occur and the cutting speed is too low; The feed rate is too large; When the main deflection angle of the reamer is too small, the worn part of the reamer is not worn, the aperture is reduced or the inner hole is not rounded, and the aperture is unqualified.

2) The solution

Replace the outer diameter size of the reamer; Appropriately increase the cutting speed and correctly use the cutting part of the sharpening reamer; When designing the reamer size, appropriately reduce the feed rate; Regularly replace the reamer with oily cutting fluid with good lubrication performance and appropriately increase the main deflection angle. The above factors should be considered or the value should be taken according to the actual situation. For experimental cutting, set aside an appropriate allowance to sharpen the reamer.

3. Superhard tool solution has a problem: the inner hole of the hinge is not round

1) Cause of occurrence

The reamer is too long, the rigidity is insufficient, and the reamer vibrates. There are sand holes and pores on the surface of the hole; The spindle is loose, there is no guide sleeve, or the clearance between the reamer and the guide sleeve is too large, and the reamer main deflection angle is too small. The surface of the inner hole with a large amount of reamer is defective and has cross holes. Thin-walled workpieces are clamped too strongly and deformed after removal.

2) The solution

Insufficient rigidity of the reamer, can use unequal spacing of the reamer. Unequal spacing reamers are adopted, and long and precise guidelines are adopted. Select qualified reserve; When reaming with equal spacing reamers is precise, adjust the spindle clearance of the machine tool, increase the matching clearance of the guide sleeve, and adopt rigid connection to increase the main deflection angle for reamer installation. Select qualified reamers and control the hole position tolerance of the previous processing process; Or adopt appropriate clamping method to reduce the clamping force.

4. Superhard tool solution has problems: the inner surface of the hole has obvious prismatic surface

1) Cause of occurrence

Reaming margin is too large; The relief angle of the cutting part of the reamer is too large; The width of the reamer edge is too wide. There are holes on the surface of the workpiece, sand holes, and the spindle runout difference is too large.

2) The solution

Reduce the amount of reamer and reduce the rear angle of the cutting part; the width of the sharpening belt; select the qualified reserve; adjust the machine spindle.

5. The problem of high surface roughness value of inner hole in super hard tool solution

1) Cause of occurrence

Cutting speed is too high; improper selection of cutting fluid The main deflection angle of the reamer is too large, the cutting part of the reamer is very poor, the blade is not sharp, and the surface is rough; the width of the reamer blade is too large, and the chip is not discharged when the reamer Excessive wear of the reamer; scratch after hitting the reamer, the reamer tip is not on the same circumference; the hinge margin is too large; there are accumulated chips on the tip of the knife; due to the material, it is not suitable for zero rake angle or negative rake angle reamers.

2) The solution

Reduce the cutting speed; Select cutting fluid according to the processing material to appropriately reduce the main deflection angle or increase the reaming allowance; Select qualified reamer; Sharpening belt width; Reduce the number of reamer teeth and increase the chip groove space according to the situation, or use reamer with edge inclination angle to grind the tip of the hinge. Appropriately reduce the reaming allowance to improve the position accuracy and quality of the bottom hole before reaming. Protective measures must be taken to avoid bumping; For damaged reaming, use extra fine oil shale to repair the damaged reamer or replace the reamer; make the chip removal smooth; replace the reamer regularly, and grind the grinding area during grinding; during grinding, use and transportation, the reamer shall be trimmed with oil shale until it is qualified, and the reamer with a front angle of 5-10 shall be used.

The above introduction is the common problems and solutions of super hard tool solutions. If you need to know more, please feel free to contact us!