Process technology for high speed cutting die

In high-speed machining mold technology, process technology is a key factor in the use of machine tools and tools. According to the current situation of domestic mold production, the process technology has largely restricted the application of high-speed machining molds. On the one hand, due to the short time of high-speed machining application, it has not formed a relatively mature and systematic process system and standard; on the other hand, the high-speed cutting process has high test cost and requires large investment and long time.

The high-speed cutting tool technology mainly includes:

(1) High-speed cutting die process test for different materials

When referring to the process parameters of high-speed milling of parts in foreign countries, it is found that the tools produced by foreign companies are tested according to the imported material standards, and the effect is more obvious when the domestically produced material molds are processed at high speed with the recommended parameters. Therefore, the use of foreign tools, in addition to the reference to the parameters provided by the manufacturer, the actual process test is also necessary.

Domestic tool manufacturers rarely recommend the technical parameters of high-speed milling. Therefore, it is more necessary to use domestically produced tools to test to obtain satisfactory process parameters. It is best to use the tools of the fixed manufacturer to form the processing technical standard through the test, and on this basis, optimize a set of processing parameters suitable for the enterprise and incorporate it into the enterprise standard.

(2) Machining tool path and programming for high speed cutting

The tool path, feed mode and feed rate in the high-speed cutting die technology are the main contents. Many tool path processing methods in high-speed cutting die technology are designed to reduce tool wear and extend tool life, so the tool's trajectory in high-speed cutting feed is much more complicated than normal machining.

The high speed machining mold process should follow the following principles:

1 When finishing with a small diameter tool, the cutting speed decreases as the hardness of the material increases.

2 Maintain a relatively stable feed rate and feed rate, continuous cutting load, reduce sudden changes, and slow forward and slow down. Avoid direct vertical downward feeding and cause chipping: the milling force of the oblique path is gradually increased, the impact on the tool and the spindle is small, and the chipping can be significantly reduced; the spiral path is cut into the blade, which is more suitable for the cavity mold. High speed machining.

3 small feed, small knife cutting. Usually the feed is less than 10% of the diameter of the milling cutter and the feed width is less than 40% of the diameter of the milling cutter.

4 Keep the uniform finishing allowance.

5 Maintain single-edge cutting.

According to the above rules, the commonly used feed path modes are as follows:

1 Try to avoid the milling movement of the straight corner; feed the cutting with a spiral at the corner to keep the cutting load stable.

2 Try to avoid the infeed and retraction movement outside the workpiece, and directly enter the next depth from the contour. Instead, the gradual progressive feed or helical cut is used.

3 Constant per-edge feed, feed the machining plane in a spiral or cycloidal path and maintain single-edge cutting. The high-speed feed milling is used for hole machining, which not only improves surface quality, but also extends tool life.

4 When the contour is machined, it is kept on the horizontal plane (contour line), and the penetration depth of each layer is the same. When entering the next depth, the feed is gradually fed.

5 When machining a small size such as a groove, use a tool with a diameter smaller than the shape and size, and feed it in a spiral or cycloidal path to maintain single-edge cutting.

The tool path processing strategy used in these high-speed cutting dies needs to be programmed. The over-complex path manual programming difficulty and workload are very large, which affects the application of high-speed cutting die technology to a certain extent, so it is best to pass the automatic programming software. achieve. High-speed cutting and finishing requires the programming of CAM, and the automatic programming software needs to adapt to the production and timely launch.

Delcam started research on high-speed machining programming technology several years ago and developed the high-speed cutting automatic programming software module PowerMILL; MasterCAM, which uses the largest amount of mold processing, has also developed the HSM software module for high-speed cutting automatic programming. Through these automatic programming software modules, the high-speed cutting path processing methods mentioned above can be realized. At present, domestic software companies are also developing high-speed cutting automatic programming software modules.

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