1. The most important tool in machining
If any tool stops working, it means that production stops. But it doesn’t mean that every tool has the same importance. The tool with the longest cutting time has a greater impact on the production cycle, so on the same premise, more attention should be paid to this tool. In addition, attention should also be paid to the machining of key components and the cutting tools with the most stringent machining tolerance range. In addition, the cutting tools with relatively poor chip control, such as drills, grooving tools and thread machining tools, should also be focused on. Shutdown due to poor chip control
2. Matching with machine tool
The tool is divided into right-hand tool and left-hand tool, so it is very important to choose the right tool. In general, the right-hand tool is suitable for CCW machines (looking in the direction of the spindle); the left-hand tool is suitable for CW machines. If you have several lathes, some hold left-hand tools, and other left-hand tools are compatible, select left-hand tools. For milling, people tend to choose more universal tools. But even though this kind of tool covers a wider range of machining, it also makes you lose the rigidity of the tool immediately, increases the deflection of the tool, reduces the cutting parameters, and is more likely to cause machining vibration. In addition, the size and weight of the tool are limited by the manipulator of tool changing. If you are purchasing a machine tool with an internal cooling through hole in the spindle, please also select a tool with an internal cooling through hole.
3. Matching with processed materials
Carbon steel is the most common material to be machined in machining, so most tools are based on the optimization of carbon steel machining design. Blade brand shall be selected according to the processed material. The tool manufacturer provides a series of tool bodies and matched blades for processing non-ferrous materials such as superalloys, titanium alloys, aluminum, composites, plastics and pure metals. When you need to process the above materials, please select the tool with matching materials. The vast majority of brands have a variety of series of cutting tools, indicating what materials are suitable for processing. For example, the 3PP series of daelement is mainly used to process aluminum alloy, the 86p series is specially used to process stainless steel, and the 6p series is specially used to process high-strength steel.
4. Cutter specification
The common mistake is that the selected turning tool specification is too small and the milling tool specification is too large. Large size turning tools are more rigid, while large size milling tools are not only more expensive, but also have longer cutting time. In general, the price of large-scale tools is higher than that of small-scale tools.
5. Choose the replaceable blade or regrinding tool
The principle to follow is simple: try to avoid grinding the tool. In addition to a few drills and end milling cutters, if conditions permit, try to choose replaceable blade type or replaceable head type cutters. This will save you labor costs and achieve stable processing results.
6. Tool material and brand
The choice of tool material and brand is closely related to the performance of the material to be processed, the maximum speed and feed rate of the machine tool. Select a more general tool brand for the material group to be processed, usually the coating alloy brand. Refer to “recommended chart of brand application” provided by tool supplier. In practical application, the common mistake is to replace the similar material grades of other tool manufacturers to try to solve the problem of tool life. If your existing cutting tool is not ideal, it is likely to bring similar results by changing the brand of other manufacturers that are close to you. In order to solve the problem, the cause of tool failure must be clarified.
7. Power requirements
The guiding principle is to make the best of everything. If you buy a milling machine with a power of 20HP, then, if the workpiece and fixture allow, select the appropriate tool and processing parameters, so that it can achieve 80% of the power of the machine tool. Pay special attention to the power / tachometer in the user manual of the machine tool, and select the cutting tool that can achieve better cutting application according to the effective power range of the machine tool power.
8. Number of cutting edges
The principle is that more is better. Buying a turning tool with twice the cutting edge does not mean paying twice the cost. In the past decade, advanced design has doubled the number of cutting edges of groovers, cutters and some milling inserts. Replace the original milling cutter with advanced milling cutter with 16 cutting edges
9. Choose integral tool or modular tool
Small cutter is more suitable for integral design; large cutter is more suitable for modular design. For large-scale tools, when the tool fails, users often want to replace only small and inexpensive parts to get new tools. This is especially true for grooving and boring tools.
10. Select single tool or multi-function tool
The smaller the workpiece, the more suitable the composite tool is. For example, a multifunctional tool can be used for compound drilling, turning, inner hole processing, thread processing and chamfering. Of course, the more complex the workpiece is, the more suitable it is for multi-functional tools. Machine tools can only bring benefits to you when they are cutting, not when they are stopped.
11. Select standard tool or non-standard special tool
With the popularization of numerical control machining center (CNC), it is generally believed that workpiece shape can be realized by programming instead of relying on cutting tools. Therefore, non-standard special tools are no longer needed. In fact, non-standard tools still account for 15% of total tool sales today. Why? The use of special tools can meet the requirements of precision workpiece size, reduce the process and shorten the processing cycle. For mass production, non-standard special tools can shorten the machining cycle and reduce the cost.
12. Chip control
Keep in mind that your goal is to process the workpiece, not the chips, but the chips can clearly reflect the cutting state of the tool. In general, there is a stereotyping of chips, as most people are not trained to interpret chips. Remember the following principle: good chips do not damage processing, bad chips are the opposite.
Most blades are designed with chip breaking slots, which are designed according to the feed rate, whether it is light cutting or heavy cutting.
The smaller the chips, the harder it is to break them. Chip control is a big problem for hard to machine materials. Although the material to be processed cannot be replaced, the tool can be updated to adjust the cutting speed, feed rate, cutting depth, tip fillet radius, etc. It is a result of comprehensive selection to optimize chip and machining.
13. Programming
In the face of tools, workpieces and CNC machine tools, it is often necessary to define the tool path. Ideally, understand the basic machine code and have advanced CAM software packages. The tool path must take into account the characteristics of the tool, such as the slope milling angle, rotation direction, feed, cutting speed, etc. Each tool has corresponding programming technology to shorten machining cycle, improve chip and reduce cutting force. Good CAM software package can save labor and improve productivity.
14. Choose innovative tools or conventional mature tools
With the development of advanced technology, the productivity of cutting tools can be doubled every 10 years. Compared with the cutting parameters recommended 10 years ago, you will find that today’s cutting tools can double the machining efficiency and reduce the cutting power by 30%. The alloy matrix of new cutting tool is stronger and more ductile, which can achieve higher cutting speed and lower cutting force. Chip breaking groove and brand have lower specificity and wider universality for application. At the same time, modern cutting tools also increase the versatility and modularity, which together reduce the inventory and expand the application of cutting tools. The development of cutting tools has also led to new product design and processing concepts, such as the overlord cutter with turning and grooving functions, the large feed milling cutter, and promoted high-speed machining, micro lubrication cooling (MQL) processing and hard turning technology. Based on the above factors and other reasons, you also need to follow up the most optimal processing method and learn the latest advanced tool technology, otherwise there is a risk of falling behind.
15. Price
Although the price of cutting tools is important, it is not as important as the production cost due to cutting tools. Although the knife has its price, the real value of the knife lies in the responsibility it performs for productivity. Generally, the tool with the lowest price is the one with the highest production cost. The price of cutting tools only accounts for 3% of the cost of parts. So focus on the productivity of the tool, not its purchase price.
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Post time: Nov-08-2019