Application of high speed machining technology

As the most important advanced manufacturing technology in mold manufacturing, high-speed machining is an advanced manufacturing technology with high efficiency, high quality and low consumption. A series of problems in conventional cutting have been solved by the application of high-speed cutting. The cutting speed and feed speed are improved in series compared with the traditional cutting process, and the cutting mechanism has also changed fundamentally. Compared with traditional cutting, high-speed cutting has made a substantial leap. The metal removal rate per unit power has increased by 30% ~ 40%, the cutting force has decreased by 30%, the cutting life of the tool has increased by 70%, the cutting heat left in the workpiece has been greatly reduced, and the low-order cutting vibration has almost disappeared.

With the increase of cutting speed, the removal rate of blank material per unit time increases, the cutting time decreases, and the processing efficiency improves, thus shortening the manufacturing cycle of products and improving the market competitiveness of products. At the same time, the small amount of fast forward of high-speed cutting reduces the cutting force, and the high-speed removal of chips reduces the cutting force and thermal stress deformation of the workpiece, and improves the possibility of cutting poor rigidity and thin-walled parts. Due to the reduction of cutting force and the increase of rotation speed, the working frequency of the cutting system is far from the low-order natural frequency of the machine tool, and the surface roughness of the workpiece is most sensitive to the low-order frequency, thus reducing the surface roughness.

In the process of machining the high hardened steel parts (hrc45-65) of the mold, high-speed cutting can replace the process of electrical machining and grinding and polishing, avoid the electrode manufacturing and time-consuming electrical machining time, and greatly reduce the amount of grinding and polishing of the fitter. High speed milling can be successfully completed for some thin-walled die workpieces that are more and more needed in the market. Moreover, on the high-speed milling CNC machining center, the mold can be clamped once to complete multi-step machining. These advantages are very suitable for die and mould industries with fast capital turnover requirements, urgent delivery time and fierce product competition.

The high-speed machining system is mainly composed of high-speed machining center, high-performance tool clamping system, high-speed cutting tools, safe and reliable high-speed machining cam software system, etc. Therefore, high-speed machining is essentially a large system engineering. With the development of cutting tool technology, high-speed machining has been applied to the processing of alloy steel (HRC > 30), and is widely used in the processing of stamping dies, injection molds and other parts in automotive and electronic components. The definition of high-speed machining depends on the type of workpiece material being processed. For example, the cutting speed used for high-speed processing of alloy steel is 500 m / min, which is the conventional down milling speed when processing aluminum alloy.

With the expansion of the application scope of high-speed machining, the research on new tool materials, the improvement of tool design structure, the generation of new NC tool path strategies and the improvement of cutting conditions have also been improved. Moreover, the computer-aided simulation technology of cutting process has also appeared. This technology is of great significance for predicting the temperature and stress of cutting tools and prolonging the service life of cutting tools. The application of casting, stamping, hot pressing and injection molding represents the expansion of the application range of high-speed cutting of cast iron, cast steel and alloy steel. In the manufacturing of stamping dies and casting molds, the industrial leading countries spend most of their research and development time on machining and polishing processes. The machining and polishing of stamping dies or casting dies account for about 2 / 3 of the total processing cost, and high-speed milling can be used to shorten the development cycle and reduce the processing cost。