New strategies to save the processing time for mold manufacturing
As a steel plate, tubes and profiles of cold forming company Eckol professional manufacturers (www.eckold.de), for industry and handicraft industry standard tooling and special tooling. Which has 130 corporate employees, one of the examples show the ability of industry to the car hood of the car rear wheel molding. 800N/mm2 by the tensile strength of high strength steel produced by mold, its inner and outer contours of the free-form surface milling, to a large extent the cost and quality of decision processes. This milling process is particularly suitable for processing in a circular outer contour and convergence with its flat surface of the cylinder. Milling, the finished product profile relative to the allowance for 0.3mm left the final preparation for finishing. Head of Klaus Bremer production so far used the tool with a round blade milling rough milling and semi-refined think outside the outline of processing when the time is too long, the durability of the tool is not satisfactory, prompting Bremer and his team search for the processing of the mold new ways.
To develop processing strategies
Eckold plant due to the company by Ingersoll provided a large number of different types of milling cutter, the cutting tool Eckold and experts in addition to regular exchange of experience, but also often discussed in the rational application of cutting tools and milling strategies. Therefore, the production of a long section is easy to Ingersoll technical consultant's recommendations into his thinking.
So far, the molding module is used with (10mm) diameter circular blade of the suite-style 35mm for rough milling, and the use of the cutting speed Vc = 180m/min, speed n = 1640r/min, feed rate Vf = 1500mm/min and depth of cut ap = 1.5mm, cutting time for 1 hour and 35 minutes. For contouring, Ingersoll's strategy is based on the three-step process: roughing, semi-finishing and finishing. Rough for key processes, technology consultants recommended three can be equipped with a blade diameter of 32mm the Form Master-Speed roughing - forming cutter. On condition that the use of cutter shank SK50 (that is, 7:24 taper tool shank, specifications for 50 - Annotation), stretching about hanging cutter 80mm. In this way, even in a higher feed rate, the tool will not generate vibration, and the precision required for processing. A first step, the use of existing standards tool Rough Form Master-Speed15VIE a radius of 24mm, height of 155.4 mm of the arc surface, through the rough outline of milling on milling to 2-3 mm above the allowance. Thus, in the second step of using another to Ingersoll's 25mm diameter cutter (model HiPos12JIF) semi-precision milling. 0.5mm to stay for the finish allowance.
Processing of the form cutter mold
Form Master-Speed-mounted screw-type milling cutter and wooden tool series is designed for roughing and semi-finishing of two-dimensional and three-dimensional outline of the development can be provided by forming screw-mounted cutter, model 15VIE, there are seven structure type, diameter from 20mm to 42mm, respectively, with 2,3 or 4 blade available. Double-edged blade can be characterized by playing with volume chip can chip off. Blade has a 10-degree angle is the axis, this is to ensure that the axial angle cut the outline of the special soft in the cutting, the cutting force acting on the main axis. Due to the length of blade 8 or 13 mm and the use of pressure to claw knife blade firmly in the seat clamp, alloy steel when it is in the processing speed of up to 160 ~ 200m/min, in the processing of gray cast iron used in 200 ~ 350m/min cutting speed is not a problem. Cutting depth of cutter design up to 1.5mm, as a result of milling cutter with high rigidity and suitable blade geometry, it is particularly suitable for cutting chrome-nickel steel. Blade due to the depth of cut ap diameter of the appropriate ratio, so that each tooth is conducive to feed the fz reached 1.5 ~ 3mm.