The latest tool requirements for mold processing (2)

(1) Multi-blade type large feed fillet end mill

The mold industry generally uses small cutting depth and large feed cutting methods to achieve efficient processing, but market demand requires further improvement of processing efficiency. In response to this need, Hitachi Tools has developed multiple cutting edge tools and coatings that can withstand high cutting speeds under high feed conditions.

The multi-blade large feed fillet tool is designed to reduce the size of the cutting edge in a limited tool outer diameter based on the previous edge number design method without reducing the edge strength. Set the major cutting edge radius of the large feed fillet end mill to R8. Compared to a circular insert of the same radius R8, it has the same edge strength, but minimizes the blade area, resulting in multi-blade. Previously, the outer diameter of the φ32 blade was 2 blades, and the multi-blade large-feed rounded end mill had 5 blades, which was 2.5 times higher than the previous products.

(2) Features of the large feed tool

The indexable tools previously used for roughing are generally equipped with round inserts. It seems that a large depth of cut can be obtained on the surface, and a large amount of material can be cut at one time, but the contact length of the cutting edge with the material to be processed is larger than that of the straight edge. The contact length of the blade, so the cutting resistance is increased, and it is difficult to achieve large feed cutting. In addition, the circular blade is subjected to a radial force in a processing where the tool overhangs for a long time, and the blade is easily bent to cause chattering. The cutting edge of the multi-edge type large feed round end mill is designed at the bottom of the rotary shaft of the tool, so the cutting resistance mainly acts on the axial direction, that is, the multi-edge type large feed round end mill is difficult to extend even if it is overhanging. Fluttering occurs and stable machining can be achieved. At the same time, by miniaturizing the blade, the cutting edge length is significantly shortened compared to the conventional large feed tool, and the cutting resistance is reduced, thereby effectively controlling the cutting force by multi-blade.

(3) Advantages of small depth of cut and large feed machining

Small depth of cut and large feed machining are the application conditions of the large feed tool, which has the advantages of high material removal rate and high processing efficiency. Compared with high-efficiency machining with large depth of cut, high-efficiency rapid feed machining can be performed within the maximum feed limit of the machine table when the depth of cut is reduced.

When the circular insert is used to increase the machining efficiency by increasing the depth of cut, the workpiece will leave a significant residue on the workpiece after machining, which will increase the processing load of the subsequent finishing tool. Although the roughing efficiency is high, it reduces the processing efficiency of subsequent processes. Compared with this, when using small depth of cut and large feed machining, the roughing of the machining residue is reduced, which is closer to the final finishing shape, thereby reducing the load of the finishing tool in the subsequent process, and roughing and finishing. The efficiency is improved at the same time, and efficient processing is realized stably and reliably.

3. Ultra-lubricating JX coating

As described above, by improving the blade shape and increasing the number of blades to improve the machining efficiency, the machining efficiency can be further improved by increasing the tool rotation speed and increasing the cutting speed and the feed speed. However, current tool coatings have insufficient heat and pressure resistance to cutting at higher than current cutting speeds. Therefore, we have re-recognized the influence of small depth of cut and large feed cutting on the cutting edge, and determined the performance required for high speed: it has the ability to suppress the friction between the chip and the tool generated by the large feed cutting even at high temperatures. performance. To this end, Hitachi Tools has successfully developed a highly lubricious titanium compound coating. This new performance JX coating for efficient processing reduces crater wear and flank wear and prevents edge sticking.

(1) JX coating with low friction coefficient, high hardness and high toughness

The JX coating adds a self-lubricating material to the titanium and aluminum compounds to form a thin oxide layer on the surface of the coating using heat of cutting. The oxide layer can improve the lubricating performance, control the cutting temperature rise, and reduce the affinity between the cutting edge and the workpiece to be processed, and suppress the bonding of the cutting edge. The hardness of the JX coating is comparable to that of the TiSiN coating with the highest hardness. The high hardness prevents the cutting edge from being worn in high-speed and high-efficiency machining environments and greatly extends the life of the tool. Ceramic hard coatings are difficult to prevent thermal cracking caused by intermittent cutting that is unique to milling, but JX coatings have a high resistance to chipping due to their high toughness. It can be seen that the JX coating is a new generation coating with both lubricity, abrasion resistance and chipping resistance. With the same number of blades and the same service life, it is 40% faster than the previous coating.

(2) High-speed cutting example of multi-blade and large-feed rounded end mill

Example of high-efficiency machining with the multi-blade large-feed rounded end mill and JX coated inserts on the latest CNC machining center machines (cutting feed speeds up to 50 m/min): multi-blade large feed The rounded end mill has an outer diameter of φ32 mm and five cutting edges; the insert grade is JX1045; the material to be processed is 40CrMnMo7 (corresponding to JIS standard SKT3). Cutting at cutting speed Vc=300mm/min, spindle speed n=3000/min, cutting feed rate Vf=50m/min, feed per tooth fz=3.3mm/tooth, depth of cut ɑp×ɑe=0.3×25mm Under the conditions, the cutting can be done lightly. The high-speed CNC machining center used in machining is not widely used at home and abroad. Compared with the high-speed CNC machining center with a cutting feed rate of 10 to 20 m/min, the machining efficiency can be increased by 2.5 to 5 times. The new generation of multi-blade large-feed rounded end mills can maximize the functionality of existing high-speed CNC machine tools.

The above describes the development purpose and effect of the Epoch deep-cut round end mill, the large feed round end mill and the JX coating developed by the latest technology. The emergence of these new tools has met the need to improve the efficiency of mold processing, and also reduced the cost of mold processing.

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