For many machining applications, there is no need to worry about whether the machine tool has enough power to complete the task you want to process. However, in some cases (usually rough machining applications), programmers / operators are required to define the power of a given tool requirement. When the machine with high speed spindle is used, because the power output at low speed is usually very low, the need to calculate power consumption is very important. For these machines, in order to make machine tools, cutting tools, and machined materials run in optimized parameters, it is usually necessary to apply smaller diameter cutters. The following information will discuss some areas that need to be pointed out, such as new tool technology used in die and mould industry today, and how to get maximum efficiency in rough machining.
Understanding the characteristics of machine tools
In order to determine whether the machine has the power to be processed under a given parameter, the relevant personnel must be familiar with their machine tool spindle power diagrams. The spindle power diagram will reveal the power and torque characteristics of the machine tool, and it is usually divided into two independent rating values (30 minutes and continuous power ratings). This picture should be used as a reference at the hand.
Estimation of power consumption
As mentioned earlier, it is very important to determine the required power value for a given tool in processing. There are many writings on how to estimate the required power values for a given material. The following information will cover the basic theory.
The common method of determining the power consumption of a given tool is the multiplication of the metal removal rate (MRR) and the power factor. The metal removal rate (MRR) is obtained by multiplying (mrr=woc*doc*F) by the cutting width of the tool used, the cutting depth and the feed rate. The power factor (P factor) is a predetermined power constant, which varies with the material. It depends on the power of a given material cutting a cubic inches per minute required value (constant power display materials in a variety of hardness values can be found in such as mechanic manual publications).
It is noted that this method of expressing power is only important in estimating the value, and many other factors also affect the power calculation. The efficiency of the spindle, the material hardness, the geometry of the tool and the blade, the cutting fluid, the tool wear and so on, all affect the power demand.
The triangular blade forms the shape of a large cutting edge that allows the higher metal removal rate.
There are many factors to be taken into consideration when the power is calculated, and the tool is one of the many factors, which is obvious. In some cases, when using the high feed tool for rough machining, the spindle will be the decisive factor to determine the diameter and processing parameters of the tool. Rough machining for any machine, especially machine tools such as CAT/BT40 and HSK40, the smaller the spindle is connected, in order to avoid undesired spindle load and cutting conditions on the maximum productivity at the same time, know how to start, so the demand for power calculation is very important. A processing power calculator has been developed, which can cover these new high feed tools and greatly reduce the time and energy needed for estimating milling, drilling and turning power consumption. By selecting and filling in some auxiliary information about tool name, tool shape, cutting speed and feed rate, programmers / operators can quickly determine whether the machine tool has enough power for the application at hand.
Tool technology for rough machining
Since you know how to produce the maximum machine tool in rough processing, it is time to discuss how to make the cutting tool produce the maximum. A new design tool specially designed for maximizing the rate of roughing metal removal has been developed, which allows for very high feed rate and a metal removal rate that can significantly reduce the processing cycle and cost during rough machining.
The tool is competent for the geometry of 2-D and 3-D parts, and it has various types and specifications.
Another option for users is to use modular tools to make the operator able to set up the suspension length and get the maximum rigidity for each application by using the flexibility obtained from different knives on the head with threaded holes.
For smaller applications, a tool with a commutable blade designed for high intake applications has been developed. The supply is 10, 12 and 16mm, and these tools are capable of very high feed (when 12mm tools are processed for steel parts, the cutting depth is 0. The feed rate is up to 300i at 025 inches. P. M.) And it can effectively improve the metal removal rate and lower the power of the equipment to the spindle machine. Compared with the whole carbide tool, the replaceable blade is still a better economic solution, and can successfully finish the hardened tool steel with a hardness less than HRC54.
A wide range of tools enable employees to effectively match the shape of cutting tools and machine tools and parts, and get the largest metal removal rate and productivity in traditional and high-speed machining centers. On many occasions, by using smaller diameter cutting tools, there will be no loss of metal removal rate and productivity. If there is any existence, if we use high input to rough machining, we can get rough machining approaching to the final shape.
In fact, when compared with other commonly used rough machining tools, the metal removal rate of the small diameter high cutting tool for rough machining is much higher than that of the larger diameter tool using traditional machining parameters and methods. Another advantage of using small diameter high feed tool is that smaller tools can get closer to the final shape of parts and reduce residual machining allowance before finishing machining.