It is not easy to process a "suitable" blade for a specific application. Not long ago, people have always thought that the shape of the blade is not a science, but an art. Because the cutting tool is very demanding in terms of wear resistance and hardness, it is very difficult to process a satisfactory groove shape.
However, the machining of the appropriate cutting edge has a large impact on tool performance and life. Proper cutting edge machining can reduce common failure causes such as splitting, thermal induced failures, and chipping to extend tool life and greatly improve tool reliability. Properly honed tools also increase the repeatability of the machining process and help unattended machining.
Blade honing is an abrasive process on a microscopic scale that requires tight process tolerances through a complete set of process controls. However, it is difficult to control metal removal rate and blade consistency on the cutting tool material. Usually, the honing process is guided by well-trained guesses and is subject to changes in the machine tool and the skill of the operator.
The ordinary honing process tends to over-machine the corners of the tool, and because the incoming materials are different, it is difficult to control on the basis of a knife and a knife. Not only is the edge honing difficult to control, but also because the cutting conditions vary with a single cutting edge, the optimum size of the machining cutting edge varies along the cutting edge as the workpiece changes.
Dr. William J. Enders, associate professor of mechanical engineering-engineering mechanics at Michigan University of Technology and president of processing and analysis technology company in Houghton, Michigan, said: "The user requires a smaller blade radius at the corner of the tool because The thickness of the cut chip decreases along the corner radius." For more than a decade, he has been studying the problem of blade processing.
On the front edge of the tool, the thickness of the uncut chips is the largest and the blade requires maximum protection. However, on the trailing edge of the tool, the thickness of the uncut chip is almost reduced to zero, so the amount of honing should be reduced accordingly. For a constant amount of honing - the size of the front edge is protected, the amount of honing on the trailing edge is greater than the thickness of the uncut swarf, so the cutting edge removes material at a very low speed and increases friction, cutting forces, temperature and wear.
Until now, the method of machining the cutting edge has not developed as fast as other aspects of the cutting tool, such as material matrix, groove shape and coating. Using its engineering microgeometry process, the company of Cresco Technology in Cresco, Pa., has introduced different sizes of edge honing techniques on different surfaces of the same tool. The process uses a dense silicon carbide fiber brush combined with computer numerical control to consistently and precisely machine the shape of the blade with a tolerance of 0.0003 inches, an order of magnitude better than most conventional honing methods.
Bill Shaffer, Executive Vice President of Conicity, said: "By controlling the blade parameters, the engineering microgeometry process stops the material removal process when the correct amount of honing is achieved. Therefore, the blade size is distributed over the cutting edge to maintain a specific uncut swarf Thickness vs. blade size ratio.†He continued: “For example, on an indexable insert or a tool holder, at the tool end radius, the edge machining combines the uncut chip thickness variation during blade machining. As the thickness of the uncut chips decreases, the size of the blade is reduced."
Cutting tools with variable cutting edges are more efficient because they change the size of the cutting edge and prevent the cut material from being caught between the tool and the workpiece. This reduces tool wear, resulting in reduced tool pressure and cutting forces and reduced tool and workpiece temperature rise. This extends tool life, improves the flatness of the workpiece surface, and reduces the formation of burrs. The variable blade can be used on almost any type of cutting tool including drills, end mills and dumplings.
The engineering micro-geometry process can also use the same edge machining process on the basis of a knife and a knife. This process has better consistency than the traditional blade processing method. In addition, the process can also implement the best micro-groove shape in every cutting application. In some cases, this means a uniform amount of honing on the entire cutting edge; in other cases, a variable honing amount is used to achieve the correct edge machining process.
One of the most obvious and immediate advantages of properly machining the blade is to increase tool life. For engineering micro-geometry, the cost of the blade processing business is typically 10% to 20% of a new replacement tool, while the process can extend the tool life by 300% to 800%.
Extending tool life is important for a number of reasons, including the cost of re-grinding and replacing new knives. For example, in order to take full advantage of its 5-axis machining center, Oberg Industries, a precision manufacturing facility in Freeport, Pa., switched from high-speed steel tools to high-performance carbide tools, using the Seim Tool company in Latrobe, Pennsylvania. The edge of the engineering micro-geometry process.
Oberg's tool room manager Bob Binner said: "By milling the edge with the engineering micro-geometry process, the time between sharpening is generally extended by about 300%, which is a huge return on the investment engineering micro-geometry process. This means reducing the number of interruptions in production and reducing labor costs."
Binner believes that more important is indirect cost savings. “This blade cutting process almost eliminates the phenomenon of broken knife. The broken knife phenomenon will have a series of adverse consequences in the automation process. The occurrence of a broken knife on the unattended machine will cause the domino effect of the downstream tool to break. This kind of failure phenomenon will be caused by Damage to tools and expensive parts can be costly, and subsequent problems can be difficult to repair. By using carbide tools with cutting edges that are engineered with micro-geometry, sometimes without changing the drill and reamer Work for a few weeks."
The economic benefits of extending tool life are particularly prominent in the aerospace and medical sectors, including the drilling and processing of tough materials such as Inconel and Titanium.
However, the machining of the appropriate cutting edge has a large impact on tool performance and life. Proper cutting edge machining can reduce common failure causes such as splitting, thermal induced failures, and chipping to extend tool life and greatly improve tool reliability. Properly honed tools also increase the repeatability of the machining process and help unattended machining.
Blade honing is an abrasive process on a microscopic scale that requires tight process tolerances through a complete set of process controls. However, it is difficult to control metal removal rate and blade consistency on the cutting tool material. Usually, the honing process is guided by well-trained guesses and is subject to changes in the machine tool and the skill of the operator.
The ordinary honing process tends to over-machine the corners of the tool, and because the incoming materials are different, it is difficult to control on the basis of a knife and a knife. Not only is the edge honing difficult to control, but also because the cutting conditions vary with a single cutting edge, the optimum size of the machining cutting edge varies along the cutting edge as the workpiece changes.
Dr. William J. Enders, associate professor of mechanical engineering-engineering mechanics at Michigan University of Technology and president of processing and analysis technology company in Houghton, Michigan, said: "The user requires a smaller blade radius at the corner of the tool because The thickness of the cut chip decreases along the corner radius." For more than a decade, he has been studying the problem of blade processing.
On the front edge of the tool, the thickness of the uncut chips is the largest and the blade requires maximum protection. However, on the trailing edge of the tool, the thickness of the uncut chip is almost reduced to zero, so the amount of honing should be reduced accordingly. For a constant amount of honing - the size of the front edge is protected, the amount of honing on the trailing edge is greater than the thickness of the uncut swarf, so the cutting edge removes material at a very low speed and increases friction, cutting forces, temperature and wear.
Until now, the method of machining the cutting edge has not developed as fast as other aspects of the cutting tool, such as material matrix, groove shape and coating. Using its engineering microgeometry process, the company of Cresco Technology in Cresco, Pa., has introduced different sizes of edge honing techniques on different surfaces of the same tool. The process uses a dense silicon carbide fiber brush combined with computer numerical control to consistently and precisely machine the shape of the blade with a tolerance of 0.0003 inches, an order of magnitude better than most conventional honing methods.
Bill Shaffer, Executive Vice President of Conicity, said: "By controlling the blade parameters, the engineering microgeometry process stops the material removal process when the correct amount of honing is achieved. Therefore, the blade size is distributed over the cutting edge to maintain a specific uncut swarf Thickness vs. blade size ratio.†He continued: “For example, on an indexable insert or a tool holder, at the tool end radius, the edge machining combines the uncut chip thickness variation during blade machining. As the thickness of the uncut chips decreases, the size of the blade is reduced."
Cutting tools with variable cutting edges are more efficient because they change the size of the cutting edge and prevent the cut material from being caught between the tool and the workpiece. This reduces tool wear, resulting in reduced tool pressure and cutting forces and reduced tool and workpiece temperature rise. This extends tool life, improves the flatness of the workpiece surface, and reduces the formation of burrs. The variable blade can be used on almost any type of cutting tool including drills, end mills and dumplings.
The engineering micro-geometry process can also use the same edge machining process on the basis of a knife and a knife. This process has better consistency than the traditional blade processing method. In addition, the process can also implement the best micro-groove shape in every cutting application. In some cases, this means a uniform amount of honing on the entire cutting edge; in other cases, a variable honing amount is used to achieve the correct edge machining process.
One of the most obvious and immediate advantages of properly machining the blade is to increase tool life. For engineering micro-geometry, the cost of the blade processing business is typically 10% to 20% of a new replacement tool, while the process can extend the tool life by 300% to 800%.
Extending tool life is important for a number of reasons, including the cost of re-grinding and replacing new knives. For example, in order to take full advantage of its 5-axis machining center, Oberg Industries, a precision manufacturing facility in Freeport, Pa., switched from high-speed steel tools to high-performance carbide tools, using the Seim Tool company in Latrobe, Pennsylvania. The edge of the engineering micro-geometry process.
Oberg's tool room manager Bob Binner said: "By milling the edge with the engineering micro-geometry process, the time between sharpening is generally extended by about 300%, which is a huge return on the investment engineering micro-geometry process. This means reducing the number of interruptions in production and reducing labor costs."
Binner believes that more important is indirect cost savings. “This blade cutting process almost eliminates the phenomenon of broken knife. The broken knife phenomenon will have a series of adverse consequences in the automation process. The occurrence of a broken knife on the unattended machine will cause the domino effect of the downstream tool to break. This kind of failure phenomenon will be caused by Damage to tools and expensive parts can be costly, and subsequent problems can be difficult to repair. By using carbide tools with cutting edges that are engineered with micro-geometry, sometimes without changing the drill and reamer Work for a few weeks."
The economic benefits of extending tool life are particularly prominent in the aerospace and medical sectors, including the drilling and processing of tough materials such as Inconel and Titanium.
Magnet Disc,Neodymium Magnet Disc,N35 Neodymium Magnet Disc
Yongze Magnet Co., Ltd. , http://www.nb-magnets.com