(4) High-speed cutting has high machining accuracy. Because the excitation frequency of the cutting of the tool is far away from the forced vibration of the process system during high-speed rotation, a good machining state is ensured. Since the cutting force is too small, the influence of cutting heat is small, the deformation of the tool and the workpiece is small, the dimensional accuracy is maintained, the friction between the workpieces is reduced, the cutting failure layer is thinned, the residual stress is small, and high precision is achieved. Low roughness processing.
(5) High-speed cutting simplifies the machining process.
High-speed cutting can achieve high machining accuracy and low surface roughness, and under certain cutting conditions, hard surfaces can be machined, especially for high hardness between HRC40~60. Part of the replacement of EDM, which is of great significance for mold processing.
Third, the application of high-speed cutting technology in mold manufacturing
The great potential of a series of features and production benefits of high-speed machining technology has long been an important technical field for German, American and Japanese countries to compete for research. Today, various commercial high-speed machine tools of different specifications produced by the United States, Germany, Japan, France, Switzerland, and Italy have entered the market and are used in aircraft, automobile and mold manufacturing.
With the introduction of high-speed cutting technology into the mold industry, it has had a great impact on the traditional mold processing technology and changed the mold processing process. Since the mold profiles are generally very complex free-form surfaces and have high hardness, it is difficult to meet the accuracy and shape requirements by conventional cutting methods. The conventional processing method is to perform milling after annealing, followed by heat treatment, grinding or electric discharge machining, and finally manual grinding and polishing, so that the processing cycle is long. In particular, manual processing time accounts for a large part of the entire processing cycle. HSC can meet the precision requirements of mold processing, reduce or even eliminate manual processing, and due to the emergence of new tool materials (such as PCD, PCBN, cermet, etc.), HSC can process workpiece materials with hardness up to HRC60 or even higher hardness. After processing the hardened mold, it replaces EDM and grinding.
High-speed milling has the advantages of high efficiency and high precision in the manufacture of molds and the ability to process high-hard materials. It has been widely used in industrialized countries. At present, China's high-speed cutting technology is still at a low level. The cutting speed used by machine tools is one order lower than that of advanced industrial countries. The production efficiency is very low and the economic benefits are not good. The application of high-speed cutting technology in the mold industry is rare, so the development of high-speed cutting is of great significance to the development of China's manufacturing industry.
High-speed cutting technology introduced to the mold industry, mainly used in the following aspects:
(1) Direct processing of hardened mold cavity. The high-speed cutting can process the hard material to directly process the hardened mold cavity, which improves the quality and efficiency of the mold processing and can replace the EDM.
(2) EDM (Electrical Spark) electrode processing. The application of high-speed cutting technology to machine electrodes has played a significant role in improving the efficiency of EDM. The high-speed cutting electrode improves the surface quality and accuracy of the electrode and reduces subsequent processing steps.
(3) Rapid sample manufacturing. It can be used to process plastic and aluminum alloy models with high-speed machining efficiency. Quickly generate 3D solid model after CAD design, which is more efficient and better than rapid prototyping.
(4) Quick repair of the mold. Molds often need to be repaired during use to prolong their service life. In the past, they were mainly done by electrical machining. Now, high-speed machining can be used to complete the work faster, and the original NC program can be used without re-programming.
Fourth, the problems of high-speed machining technology
High-speed machining technology is one of the main directions in the development of cutting technology. In addition to relying on the development of numerical control technology, microelectronics technology, new materials and novel components, CAD/CAM and other basic technologies, it also has a series of urgent needs to overcome. Technical problems, such as serious tool wear, high-speed cutting tool cutting and cutting problems, high-speed cutting tool materials are expensive, milling, boring and other rotary tools and spindles need dynamic balance, tool clamping must be safe and secure, the spindle system is expensive and The short life, and the high-speed machining machine and its control system are expensive, which makes the one-time investment of high-speed cutting large. These problems restrict the further popularization and application of high-speed cutting.
V. Conclusion
High-speed machining technology is an advanced manufacturing technology with broad application prospects. Replacing EDM (or most of them) with high-speed machining is a major step in speeding up mold development and achieving process replacement. The application of high-speed cutting technology to the mold manufacturing industry can not only greatly improve the efficiency, quality and cost of machining, but also drive the development of a series of high-tech industries. Therefore, we are currently strengthening the basic research of high-speed cutting technology, establishing high-speed cutting database, high-speed cutting safety technology standards, improving the development and innovation capabilities of the machine tool and tool industry, and accelerating the research and development and industrialization of high-speed cutting tool systems and high-speed cutting machine tools. It is a priority.
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