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Tungsten carbide cutter milling method
  • Date:16-11-17 08:25
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Tungsten carbide cutter milling method
In order to ensure the smooth surface milling carried out before starting the milling, the whole process has a clear estimate. Is a rough milling or fine milling to? Machined surface will be used as benchmarks? Milling the surface roughness, dimensional accuracy how big changes? In addition, you also need to choose the right milling cutter cutting parameters. This paper analyses the need to take into account the key content.
The choice of milling cutter
Milling cutter is more expensive, 100mm face milling cutter diameter price to more than $600, so should be chosen carefully to achieve truly fit for the specific processing needs.
First of all, when you are selecting a milling cutter, taking into account the number of teeth. For example 100mm diameter of only 6 tooth milling cutter with coarse teeth, while diameter is 100mm the movable milling cutter with 8 teeth. Pitch while in determines the size of milling cutters involved in cutting the number of affects the smoothness of cut and cutting rate of the machine tool requirements. Each milling cutter manufacturer has its own set of coarse teeth, movable milling cutter series. 
For heavy-duty rough milling, excessive cutting force can be made less rigid machine tool chatter. This vibration can lead to carbide cutting edge, so as to shorten tool life. Used milling cutter with coarse teeth can reduce the machine power requirements. So when the spindle hole size is smaller (such as R-8, 30#, 40# cone hole), you can use effective milling milling cutter with coarse teeth.
Milling cutter with coarse teeth used for rough, because it has a large chip grooves. If the chip grooves is not large enough, will result in volumes is difficult or cutting with blade, workpiece frictions. Under the same feed speed, milling cutter with coarse teeth each cutting tooth milling cutter to load key.
Precision milling cutting depth is shallow, typically 0.25~0.64mm, each tooth of the cutting load of small (about 0.05~0.15mm), the power required is small, can select the movable milling cutters, and can choose to use a large feed. Due to the limited precision milling of metal removal rate, key chip tooth milling cutter Groove smaller anyway.
Taper hole of the bigger, better rigidity spindle movable milling cutters can also be used for rough milling. Because the movable milling cutter at the same time there are more involved in cutting, when with a large depth of cut (1.27~5mm), note the machine power and rigid enough, Mills chip slot if it is big enough. Chip need to be tested, if the chip problem, should adjust the cutting.
Blade options
Processing selection pressing the blade is only suitable for some, sometimes also need to select the grinding blades. Rough best selection of suppressing the blade, which can reduce the processing costs. Suppressing size and sharp edge of the blade than a polished blade is poor, but suppressed the cutting edges of the blade with better strength, impact resistance and can withstand rough large depth of cut and feed rate. Suppressed blade with chip grooves sometimes rake reduces cutting force, while also reducing friction with the workpiece, chips and lower power requirements.
But the suppressed blade surface is not as close as the grinding blades, poor dimensional accuracy, in the milling cutter on the tip height difference of more. Due to the suppressed blade cheap, so widely used in production.
Precision milling, best selection of grinding blade. This blade has better dimensional accuracy, so the blade in the milling of high positioning accuracy, better accuracy and surface roughness can be obtained. In addition, the grinding milling for finishing the development trend is grinding out chip slots, forming large, positive cutting edges, allow the blade on the small feed, the cutting depth the cutting. Without a sharp rake carbide insert when using small feed, the cutting processing time, tip friction parts, shorter tool life.
Ground angle blade, can be used to mill a viscous material (such as stainless steel). By sharp knife blade shearing, reduces the friction between the blade and the workpiece material, and chip quickly from the front blade to leave.
As another combination, pressing the blade can be mounted on most of the milling cutter blade, and then configures a grinding scraping blade. Scraping blade to clear rough cut, rather than just pressing the blade can get better surface roughness. And scraping blades can reduce cycle time, and reduce costs. Scraping technique is an advanced technology, is already turning, grooving cutting and drilling applications.
Cooling and coated
Plane milling is cool, is controversial. When using a large diameter face mill milling, coolant to spray the entire cutter. Especially the mill belonging to the intermittent processing. Blade frequently to cut, cut out, actually coolant up to the tip, but a tip to cut heating and is cooled cut out. This heating, cooling quickly, can easily cause cracking. If the blade cracks and falling from the blades when cutting, blade would be seriously damaged. Amoy moisturizing oil already sold net up fish face chest small effective cosmetic mirror which makes good lotion scar repair which is good
Modern tools can greatly reduce the probability of temperature crack and promoted the development of dry cutting. Especially TiAlN coated tools are suitable for dry cutting. Because when you cut into the metal, cutting calories makes TiAlN chemical changes on the surface, resulting in a more rigid material.
Advantages of dry cutting is that the operator can see the chips the actual shapes and colors, cutting process of evaluation information is provided for the operator, due to the different chemical compositions of the workpiece, sent the message is not the same when when machining carbon steels to form dark brown chips, using proper cutting speed when speed is further improved, Brown chip will turn blue. If the black chip, shows that cutting temperature is too high, the cutting speed should be reduced.
Stainless steel and low thermal conductivity, heat is not well transmitted to the chip, so processing of stainless steel should use appropriate cutting speed, make chips with a hint of Brown. If you chip into a dark brown, which shows that the cutting speed has reached maximum limit. Sometimes, to avoid the knife, and stainless steel cutting heat is needed. In addition, the cooling liquid cooling too fast the chip fuse blade, led to lower tool life.
Excessive accumulation of feed material, and the feed rate too low will cause friction in the tool and the workpiece, can also cause overheating.
Dry cutting aims to adjustment of cutting speed and feed rate, heat to chip instead of on the workpiece or cutter. Therefore, you should avoid using the coolant to see flying chips, suitably adjust spindle speed and feed rate. Eager chip means heat is not passed on to the parts and tools, will not crack, thereby extending tool life. But when flammable materials (such as titanium and magnesium), should pay attention to cooling and fire-fighting facilities.
It is worth mentioning that, when dry-cutting, thread milling cutters of the surface should be coated with a small amount to prevent the "killed" (difficulty demolition) compounds are also important, but be careful not to bring into the dirt, otherwise it will affect cutter precision. 
Climb milling and conventional milling
Most of the surface milling with lead screw or ball screw light machine with milling to complete. However, you should try to climb, this will achieve a better effect. When milling, arose before the blade cut into the strong friction and causes hardening of the surface, making the next cutter to cut. When you climb milling, milling width should be approximately equal to 2/3 milling cutter diameter, which ensures that the blade immediately cut into the workpiece at the outset, there is little friction. If it is less than 1/2 milling cutter diameter, blade began "rubbing" artifacts, because cutting thickness when cutting smaller, feed per tooth will be reduced because of the narrowing of the radial width of cut. "Friction" results in shorter tool life, cemented carbide tool, increase feed per tooth, and decrease the cutting depth is more favourable. So when the rough milling, if the radial width of cut is smaller than the Cutter radius, increase the amount of passes, of its tool life will increase, shortening of the processing time. Of course, precision milling need the smooth surface, you should limit the amount of passes.
Try adjusting this radial milling width to determine radial milling milling cutter diameter and width of work, preferably in the high-precision machine tools, so that adjustments at the same time, to observe the changes of workpiece surface roughness. 
Milling efficiency evaluation
Face milling productivity can be measured in a variety of ways, one is by making sure the metal removal per minute, namely: WOC (cutting width) xDOC (cutting depth) xFR (passes). Example: 3 (WOC) x0.150 inch (DOC) X3.5-inch/minFR=15.75 cubic inches per minute. Metal removal rate is cut the volume of metal, used in machine tool power can achieve the rate depends on the hardness of machined metal. Thus there is another way to measure, that is required for direct calculation of milling rate. It is equal to: metal removal rate x coefficient of material hardness. Such as: hardness coefficient of aluminum is about 0.3, 15.75x0.3=4.725 required power (HP), 4140 steel hardness coefficient of about 0.7, 15.75x0.7=11 required power (HP), hardness coefficient available information on manuals, etc!
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