1. Reasonable selection of milling tools with different number of teeth
Coarse tooth cutters are uneven pitch cutters. Due to their wide flutes, they are suitable for milling long chip metals such as stainless steel and aluminum alloys. Additionally, the cutter has fewer teeth to mill metal at the same time. time, the cutting force generated is small and is suitable for small electric spindle machines or workpieces with weak parts.
Fine-tooth cutters are cutters with a moderate number of teeth and a wide range of versatility. They are generally recommended as the first choice. When the milling cutting force needs to be small, the method of reducing the number of blades is generally adopted, but adjacent blades should be removed evenly.
Special density tooth milling cutters are used in machine tools with sufficient spindle power. When the workpiece is properly clamped, high efficiency metal removal rates with large depth of cut and large tool passes can be achieved. It is also suitable for milling metals such as gray cast iron which require low chipping tolerance.
2. Reasonable selection of tool diameter
The choice of cutter diameter is generally based on the width of the workpiece and the effective power of the machine tool. By convention, the diameter of the cutter is selected according to the size of the part and in particular the milling width of the part, but for a given face milling cutter. , its optimal milling The width is 70 to 80% of the nominal diameter of the cutter. By making the milling width approximately equal to 2/3 of the cutter diameter, the cutting edge immediately cuts the workpiece at the start, with almost no friction. The milling width is less than half the cutter diameter and. the cutting edge begins to “rub” the piece. When rough milling, if the radial When the cutting width is less than 2/3 of the cutter diameter, increasing the tool feed will increase the tool life.
3. Reasonable selection of the main declination angle of the tool
The main declination angle is the angle formed by the body of the cutter and the leading edge of the insert. The main declination angle will affect chip thickness, cutting force and tool life. If the main declination angle is reduced at a given feed rate, the main declination angle is the angle formed by the body of the cutter and the leading edge of the insert. the cutting thickness will be reduced, in fact, the cutting edge contacts the workpiece in a wider range, thereby reducing the main deviation angle. The cutting edge gradually cuts or withdraws from the workpiece surface, which helps to reduce radial pressure, protect the blade edge, and reduce the probability of cutting edge breakage. However, its negative impact is that it will cause an increase. in axial pressure, which makes the machining of thin section parts difficult. The possibility of vibrations increases and causes deviations on the machined surface.
4. Reasonable selection of milling inserts
It is better to use stamped blades for rough machining, which can reduce processing costs. The dimensional accuracy and sharpness of pressed blades are worse than those of ground blades, but the edge strength of pressed blades is better, resistant to impact during rough machining, and can withstand greater cutting depths and feeds. Pressed inserts sometimes have chip grooves on the cutting surface, which can reduce cutting force, while also reducing friction with the workpiece and chips, thereby reducing power requirements. However, the surface of the pressed blade is not as narrow as that of the sharpened blade, and the dimensional accuracy is poor. The height of each tool tip on the cutter body is very different. Since pressed blades are cheap, they are widely used in production.
For fine milling, it is best to use ground inserts. This type of insert has better dimensional accuracy, so the positioning accuracy of the cutting edge during milling is higher, and better machining accuracy and surface roughness can be achieved. In addition, the development trend of ground milling inserts used for finishing is to grind chip grooves to form cutting edges with large positive rake angle, allowing the inserts to cut with small feeds and low cutting depths. For carbide inserts without sharp cutting angles, when machining with low feed and low cutting depth, the tool tip will rub against the workpiece and the tool life will be short.
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