During high-speed cutting, the tool needs to have high geometric accuracy, repeat positioning accuracy of clamping, high rigidity, and safety and reliability of high-speed dynamic balance. These requirements are necessary because of the influence of centrifugal force and vibration. Because high-speed cutting is characterized by a large centrifugal force and vibration, the conventional 7:24 taper tool holder system exhibits obvious defects during high-speed cutting. These defects include insufficient rigidity, low repeat positioning accuracy, and unstable axial dimensions. These defects are caused by the zinc die casting manufacturer characteristics of large centrifugal force and vibration. The tool's ability to maintain its dynamic balance is negatively impacted as a result of the expansion of the tool, which causes a shift in the location of the center of mass of both the tool and the clamping mechanism.

At the moment, the heat-expanding and cold-shrinking fastening tool holders as well as the HSK high-speed tool holders are very popular in other countries. Tool holders for fastening that are resistant to thermal expansion and cold contraction are equipped with a heating system. In most cases, the tool holders make use of the taper so that they can simultaneously make contact with the end surface of the spindle. The rigidity is improved, but there is a significant decrease in the tool changeability. knives can only be installed in one tool holder at a time using one particular connection diameter. Because of the relatively high cost of this type of heating system, the HSK type tool holder system may be utilized during the beginning stages of the process. When an organization has more than three high-speed machine tools, it is in their best interest to use thermal expansion and cold contraction fastening tool holders. This is because these tool holders allow for expansion and contraction in response to temperature changes.

When performing high-speed cutting, the tool is one of the most important and active factors to consider. This factor has a direct impact on the processing efficiency, as well as the manufacturing cost and product processing accuracy. In order for high-speed machining to be successful, the cutting tool must be able to withstand high temperatures, high pressures, friction, impact, and vibration, amongst other loads. The high-speed cutting tool needs to have good mechanical properties and thermal stability, which means it can withstand impacts well, doesn't wear out easily, and can withstand thermal fatigue. The tool technology that is used for high-speed cutting has undergone rapid development, and more applications, such as diamond (PCD), cubic boron nitride (CBN), ceramic tools, coated carbide, and (carbon) titanium nitride carbide TIC (N), are on the horizon.

Cemented carbide is the material that is most frequently utilized for use in cutting tools for the purpose of machining cast iron and alloy steel. The wear resistance of tools made from cemented carbide is excellent, but their hardness is inferior to that of tools made from cubic boron nitride and ceramics. Titanium nitride (TiN), titanium aluminum nitride (TiALN), and other materials are used as coatings in the tool coating technology that has been adopted in order to improve the surface finish and the hardness of the material. One of the most important technologies for enhancing high-speed cutting capabilities is coating technology, which makes it possible for a coating to evolve from a single coating to a multi-layer coating with multiple coating materials. This has become one of the key technologies in recent years. The diameter ranges from 10 to 40 millimeters, and the tools coated with titanium aluminum nitride are able to process materials with a Rockwell hardness of 42 or higher, whereas the cemented carbide inserts coated with titanium carbonitride can only process materials with a Rockwell hardness of less than 42.

When cutting steel at high speeds, the tool material should be P-type cemented carbide with high thermal hardness and fatigue strength. Other suitable options include coated carbide, cubic boron nitride (CBN), and CBN composite tool material (WBN), among other options. When cutting cast iron, the rough machining should be done with composite silicon nitride ceramics or polycrystalline cubic boron nitride (PCNB) composite tools, and the finishing machining should be done with fine-grain K-type cemented carbide.

When performing precision machining on non-ferrous metals or materials that are not metallic, polycrystalline diamond PCD or CVD diamond-coated tools are the best option. The idea of effective diameter is important to keep in mind when choosing cutting parameters for round inserts and ball nose milling cutters. This is because effective diameter affects the amount of material removed from the cutting zone. Design and production of high-speed milling tools ought to be done in accordance with the principle of dynamic balance. The rake angle of the tool is narrower than the rake angle of traditional tools, while the relief angle is marginally more expansive. To increase the corner angle and prevent thermal wear at the corner, the connection between the main cutting edge and the auxiliary cutting edge should be rounded or chamfered. In order to improve the rigidity of the tool, both the length of the cutting edge close to the tool tip and the volume of the material that makes up the tool should be lengthened.

Under the conditions of ensuring safety and satisfying processing requirements, the overhang of the tool ought to be as short as is practically possible, and the center of the tool body ought to have a higher level of toughness. The connecting shank is tapered to increase the rigidity of the overall structure, and the shank itself is thicker than the diameter of the tool. You should make an effort to leave a coolant hole in the middle of the tool and the tool system. It is important to take into consideration the effective cutting length of the ball end mill, and the cutting edge should be as short as is practically possible. Rough milling of complex surfaces is typically performed with two-helical groove ball end mills, while fine milling of complex surfaces is typically performed with four-helical groove ball end mills.

In order to prevent unexpected shifts in the feed direction, the radius of curvature of the finishing surface ought to be greater than 1. 5 times the radius of the tool. In the high-speed finishing of the mold, when cutting in and out of the workpiece each time, the change of the feed direction should adopt arc or curve transfer as much as possible, and avoid straight-line transfer in order to maintain the stability of the cutting process. This is done to ensure that Surface Finish Services the mold is cut cleanly and accurately.

Strategies such as three-dimensional offset, contour finishing, optimal contour finishing, and spiral contour finishing are included in high-speed finishing strategies. Other strategies may also be included. These strategies ensure a smooth and stable cutting process, which in turn ensures rapid material removal from the workpiece, which in turn results in high-precision cutting surfaces that are smooth. The primary goals of finishing are to achieve a high level of precision, ensure that the surface quality Sandblasting Services of the parts is smooth, and make the processing of fine areas, such as small fillets, grooves, etc. , as simple as possible. Utilizing a 3D helical strategy for finishing is going to be the most successful method for many different kinds of shapes. When you use this strategy, you will not have to make the frequent direction changes that are present in the parallel and offset finishing strategies. As a result, the machining speeds will be higher, and there will be less tool wear.

Using this tactic will result in a toolpath that die casting mold is continuous, smooth, and has very little tool lift. This method of machining combines the benefits of two different machining strategies, namely spiral machining and contour machining. It is possible to cut down on the amount of time spent machining, the tool load is more stable, there are fewer tool lifts, the time spent machining can be reduced, and there is a lower chance of tool damage. In addition to this, it enhances the quality of the machined surface and reduces the amount of hand sanding that is required after finishing. In many instances, it is necessary to combine the contour finishing of steep areas with the three-dimensional equidistant finishing of flat areas. This is because of the nature of the terrain in these areas.