Mold milling cutter typical product processing case introduction

Release time:

2022-08-04

In the forming and manufacturing of modern molds, with the improvement of the aesthetics and functional requirements of new products in machinery and electronics, automobiles, home appliances and other industries, more and more complex parts make the mold surface increasingly complex, and the proportion of free-form surfaces is increasing. This puts forward higher requirements for mold processing technology. Due to the complex structure of the mold, high precision requirements, different parts of the surface characteristics and materials have a larger difference, the use of mold milling cutter is also different, this paper on the mold milling cutter typical processing case rough introduction.

(I) Zhuzhou diamond XMR01 series large feed milling cutter

(1) Application areas. Large feed milling cutter in the mold industry has a wide range of applications, the processing efficiency is higher than the copying tool, which uses the quadrilateral blade tool is mainly used in plane milling, W-shaped blade tool for cavity milling.

(2) Tool characteristics

1) the cutting efficiency is high, the small installation of the blade main angle reduces the radial force generated during cutting, minimizes the tool vibration, and greatly improves the feed speed.

2) In most cases, it can replace the traditional circular blade. Compared with the circular blade, it has a smaller main deflection angle and a wider light edge, and can efficiently remove the blank allowance.

3) During bevel processing and spiral processing, the feed speed needs to be reduced. During drilling, the axial feed is set below 0.2mm/r, and long chips fly out. Pay attention to safety. During spiral reaming, the weekly back cutting amount cannot exceed the maximum back cutting amount ap;S-shaped inserts can also be inserted and milled (see Figure 4-93).

Figure 4-93 Bevel and spiral machining

4) There are 2 types of blades: Z type and S type; the installation interface has a straight handle interface and a sleeve interface with an end key.

(3)XMR01 series milling cutter features. The characteristic of the large feed tool is to dissolve the main cutting force to the axial direction, greatly reduce the radial component force, and improve the impact resistance of the tool. In addition, this structure can effectively reduce vibration in large overhang milling (see Figure 4-94).

Figure 4-94 XMR01 Series Milling Cutter

a) Milling cutter assembly drawing B) Blade c) Processing schematic diagram

(4)XMR01 series tool typical application case (processing mold)

1) customer name: a domestic mold manufacturing plant.

2) Part name: female die.

3) Processing material: 45 steel.

4) Cooling method: dry type.

5) Processing method: equal height rough machining.

6) cutter: XMR01-063-A22-WP08-04, blade: WPGT080615ZSR, blade brand: YBM351.

7) original tool: TXP08-63-22 (a foreign brand), the original blade: RB7025/XPKT08T516TR.

8) Cutting parameters: vc = 800r/min,ap = 1.2mm,vf = 4000 mm/min.

9) Trial results: tool processing 180min,RB7025 processing 157min, cutting performance is better than the brand of imported tools.

(5)XMR01 series tool typical application case (processing forged steel)

1) customer name: a domestic heavy machinery company.

2) Part name: automobile fuel tank guard plate mold.

3) Processing material: 55 forged steel.

4) Cooling method: dry cutting.

5) processing method: plane milling; spiral interpolation processing.

6) Pre-drilled hole diameter: φ45mm, cutting diameter: 115mm, total processing depth: 60mm.

7) cutter: XMR01-063-A22-WP08-04, blade: WPGT080615ZSR, blade brand: YBG212.

8) Original tool: FCP05 X65.080AN-1 (a foreign brand), blade brand: LC280TT (a foreign brand).

9) Cutting parameters: n = 610r/min,vc = 120 m/min,ap = 2mm,vf = 1500~2000 mm/min.

10) Machining effect: face milling: the tool performs well in trial cutting, with little wear of the tool fitted with blades, no edge chipping, and good rigidity and toughness. Spiral interpolation milling: it performs well in trial cutting, especially in spiral interpolation milling, with uniform blade wear and good rigidity and toughness.

11) The overall performance of XMR tools tested in face milling and spiral interpolation milling is better than that of imported tools of this brand.

(II) European machine finishing ball end mold milling cutter

Oslar has developed an indexable finishing ball end mill PFB (see Figure 4-95) to meet the evolving processing needs of the mold industry. PFB has 3 different types of cutter body to choose from, including steel cutter body, short shank type cemented carbide cutter body and long shank type cemented carbide cutter body, with shank diameter of φ8 ~ φ32mm.

Fig. 4-95 Ball End Milling Cutter PFB

At the same time, there are 4 kinds of blade materials to choose from. Customers can choose the most suitable knife body and blade according to the specific processing conditions and processing materials, as shown in Table 4-22 and Table 4-23.

Table 4-22 Blade Performance

Table 4-23 Specific Processing Effect of PFB

(III) mountain high fast feed milling cutter

The main deflection angle of the tool using the fast feed milling method is small, the radial force of the milling cutter is small, and the axial force is large; therefore, the risk of vibration during the processing is low, and the processing is stable. Especially when the tool overhang is long, relatively high cutting parameters can be used due to the small vibration. Fast feed processing tool, the main deflection angle is small, back to eat the amount of the knife is shallow, but the part of the cutting edge involved in the cutting is longer, so the edge strength is relatively high. This processing method has a larger feed per tooth and a faster feed speed; it helps to reduce the occurrence of work hardening and the continuous accumulation of cutting heat on the cutter body; therefore, it is suitable for cutting difficult-to-machine materials such as high-temperature alloys.

1.Jabro full hard fast feed milling cutter is a perfect tool series for small workpieces and small cavities (see Figure 4-96). JHF980 is suitable for machining steel, stainless steel, cast iron and super alloys. JHF180 is suitable for processing hardened steel.

Figure 4-96 Jabro Full Hard Fast-feed Milling Cutter

2.Minimaster the small devil fast-forward milling cutter is in the range of φ8 ~ φ12mm, Jabro whole hard end milling cutter has better rigidity, so it should be selected for applications with small amount of back cutting.

The Minimaster demon (see Figure 4-97) provides great flexibility, with different shank forms for each diameter, allowing the best tool length to be selected for a specific application.

Figure 4-97 Minimaster Little Devil Fast Forward Milling Cutter

3.R217/220.21 convex triangle series fast feed milling cutter fixed insert seat series, including cutter bar and cutter disc type end mill cutter body. Suitable for applications such as face milling, cavity milling, spiral interpolation milling and plunge milling.

R220.21: Cutter disc type end mill cutter body.

R217.21: Various types of cutter bar.

218.19 blade: contains 4 different specifications, can cover the diameter range of φ16 ~ φ208mm. Wide selection of cutting groove shapes and material grades for all types of materials (see Figure 4-98).

Figure 4-98 R217/220.21 Convex Triangle Series Fast-feed Milling Cutter

4.SC12 square fast feed series SCET120630T blade: 6.35mm thickness. Blade type with a tip arc radius of 3.0mm. Mainly used for heavy-duty roughing applications in stable working conditions. Suitable for milling operations when the tool is horizontal to the workpiece (see Figure 4-99).

Figure 4-99 SC12 Square Fast Forward Series

5.HF2, HF4 series fast feed milling cutter L-shaped inserts are a new series of small diameter high feed tools, designed to provide ultra-high productivity for modern CNC machine tools. The cross section and thickness of the large insert can improve the strength, and the outer arc can prevent the cutting edge from micro-chipping. The "good dynamic balance design" of the cutter body and the insert enables smooth chip removal during cavity profiling milling, especially when using a long overhanging handle. LO type double-sided inserts provide higher processing efficiency and economy. At the same time, it has the corresponding inch size and complete blade material grade and groove shape, which can cover a wide range of materials including hardened steel, stainless steel and high temperature alloy (see Figure 4-100).

Figure 4-100 HF2, HF4 series fast feed milling cutter

6.HF6 double convex triangle series has 6 effective cutting edge design, ME13, M15, MD17 three groove design, combined with different blade materials, applied to different workpiece materials (see Figure 4-101).

Figure 4-101 HF6 double convex triangle series

7. Double-sided Wang Fast Feed ON09 series with 16 effective cutting edges has high axial and radial accuracy with its unique insert seat design. Provide longer and predictable tool life; Use the same blade R220.48-ON09 as the double-sided king cutter body (belonging to the range of double-sided king milling cutter series),16 effective cutting edges, providing excellent economy; reduce blade inventory (use the same blade type as the double-sided king knife body); the knife body with a nickel-plated coating on the surface provides a longer life of the knife body (see Figure 4-102).

Figure 4-102 ON09 Series

a) Partial assembly drawing of milling cutter B) Assembly drawing of milling cutter

(IV) tycolo milling cutter

1. DoFeed large feed milling cutter

(1) Product introduction. Since its introduction, DoFeed large feed milling cutter (see Figure 4-103) has been widely used in mold, aerospace, power generation and other fields, and is suitable for high-efficiency rough machining of face milling, groove milling, cavity milling, slope milling, plunge milling and spiral milling of steel, stainless steel, cast iron, titanium alloy, nickel-based alloy and hardened steel.

Figure 4-103 DoFeed Large Feed Milling Cutter

(2) Product characteristics. Very economical 4 cutting edge insert design, cutter body with cooling hole design can ensure smooth chip removal, low resistance geometric structure design ensures vibration-free cutting, EXN03 milling cutter is suitable for efficient processing of medium and small power machine tools, EXN06 milling cutter is suitable for efficient processing of medium to high power machine tools, and 4 kinds of insert materials can meet the processing requirements of various materials.

(3) Application examples

1) Workpiece name: aviation structural part (see Figure 4-104).

Figure 4-104 Aviation Structural Parts

2) Workpiece material: titanium alloy.

3) Application: cavity milling.

4) Machine tool: MC machining center, BT50 powerful tool holder.

5) Cutting fluid: water soluble.

6) Tool bar: EXN03R025M25.0-05, blade: LNMU06X5ZER-ML AH725.

7) Cutting parameters: vc = 40 m/min,fz = 0.7mm/z,vf = 1790 mm/min,ap = 0.5mm.

8) cutting effect: the processing efficiency is 3.3 times of the original tool.

2. Tacolo BallFinishNose high-precision mold profiling milling cutter

(1) Product introduction. BallFinishNose high-precision indexable mold milling cutter (see Figure 4-105) adopts a unique locking mechanism and a new cooling and conveying system design, which has become the recommend tool used in the mold industry. Asymmetric blade positioning shape design can ensure a reliable locking, the mechanism helps to achieve good surface accuracy and long and stable tool life.

Figure 4-105 BallFinishNose high-precision indexable mold milling cutter

(2) Product features

1) The asymmetric blade improves the repeated positioning accuracy of the indexable blade, ensuring minimal runout and high precision.

2) Two series of blades, ball head blades and rounded blades, can meet the processing needs of the mold industry.

3) The high-precision ball head blade can be used for high-precision 3D processing.

4) There are 3 directions of channels on the blade to provide sufficient cutting fluid for the cutting edge.

(3) Application examples

1) Workpiece name: auto parts mold (see Figure 4-106).

Figure 4-106 Auto Parts Mold

2) Workpiece material: SKD11(60HRC).

3) Application: copying processing.

4) Machine tool: horizontal machining center, BT50 tool holder.

5) Cutting fluid: internal cooling.

6) Tool bar: EBFM20S20C220, blade: ZFBM200R00-MJ AH710.

7) Cutting parameters: vc = 283 m/min,fz = 0.39mm/z,ap = 0.15mm.

8) processing effect: tool life increased by 1.3 times.

(V) arrow stone milling cutter

Rapid milling cutter is also called high feed milling cutter, its principle is through the end of the tooth shape design, reduce the radial cutting force of the milling cutter, increase the axial cutting force of the milling cutter, so as to use the characteristics of high compressive strength of hard alloy, to achieve the purpose of rapid removal of machining allowance, so compared to ordinary milling cutter, with greater overhang elongation, greater cutting volume per tooth.

1. Changeable cutter head type quick milling cutter

(1) Product introduction. The replaceable cutter head type end mill (see Figure 4-107) is one of the development directions of carbide milling cutters. Many of the world's top cutter companies have launched similar products. Due to the characteristics of fast milling cutters, they are not as sensitive to the processing depth as ordinary milling cutters, so they can process large overhanging grooves or surfaces. Specifications: φ8mm, φ10mm, φ12mm, φ16mm, φ20mm and φ25mm.

Fig. 4-107 Quick milling cutter with replaceable cutter head

a) Milling cutter and cutter head B) Milling cutter serialization

(2) Product features

1) The production efficiency is high, and the feed rate can reach 1~1.6mm/r.

2) Using short cone and T-shaped thread positioning, reliable connection, high positioning accuracy, coaxiality ≤ 0.015mm.

3) The cutter bar can be applied to a variety of cutter heads.

4) Low cost, replace the cutter head after wear.

5) The maximum processing depth can reach more than 6 times the diameter.

(3) Application examples

1) Parts: non-free-form integral impeller (see Figure 4-108).

Figure 4-108 Non-free-form integral impeller

a) Impeller workpiece B) Processing site diagram

2) Part material: FV520B.

3) Part size: φ16mm fast milling cutter rough milling impeller runner groove.

4) Processing parameters: vc = 100 m/min,ap = 1mm, AE = 16mm,f = 1.6mm/r.

5) Processing life: continuous processing for 90min.

2.YESTOOLS solid carbide fast milling cutter

(1) Product introduction. The use of European imports of ultrafine particle carbide bar, with the application of nano-scale PVD coating, strict production process control, rigorous edge post-processing procedures, greatly reduce the possibility of edge collapse, making the use of high speed, high feed processing possible (see Figure 4-109).