Application of the hottest high speed milling tech

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Application of high-speed milling technology in plastic mold processing

at present, plastic molds are becoming more and more sophisticated, the structure is becoming more and more complex, and the whole mold is becoming more and more precise. The mold closing times required by the mold are close to or more than 800000 times. The mechanical testing machine of mold steel used by foreign plastic mold manufacturers is a product combining modern electronic skills and mechanical transmission skills, and the hardness of the product is getting higher and higher, and some even exceed HRC 64, But the delivery time of the mould is required to be shorter and shorter. These market characteristics have brought great pressure to mold manufacturers. The emergence of high-speed milling technology has brought new development opportunities for mold manufacturing, especially in small and medium-sized precision plastic processing

reduce the number of processes in plastic mold processing and shorten the delivery time of molds

the high efficiency of high-speed cutting is not only reflected in the reduction of machine tool processing time, but also in the reduction of the overall process time. With higher cutting speed, less machining allowance, denser tool path and less cutting depth during finishing, especially on free-form surfaces (the cutting depth is generally 0.02 to 0.1mm, for example, when using small tool diameters, such as 0..8mm diameter tools, the cutting depth is as small as (0..02mm). Fine and tight tool paths will generally greatly improve the finish of the machined surface. Replacing the conventional slow heavy cutting with fast and fine light cutting will greatly simplify the subsequent process. For example, the manual polishing time can be shortened by 60%-100%, and the EDM process and time can also be reduced. This saving has been truly reflected in many foreign mold manufacturers

it can process thin-walled ribs and root cleaning of small diameter tools

because the high-speed milling machine tool greatly improves the spindle speed, the dynamic balance performance of the spindle and the stability of the machine tool, under the same tool diameter, it can get a larger cutting speed, so that the processing method of light cutting can be realized on the surface of the tool and the workpiece, and the cutting force in the cutting area can be greatly reduced. Therefore, it can process thin walls or ribs of more than 0.1mm, and bring great convenience to the small fillet root cleaning of the precision mold. Even when the hardness of the mold material reaches hrc54, a tool with a diameter of 0.3mm can be used for milling operation. This can greatly reduce the number of electrodes, but also reduce the EDM time

before using high-speed milling, the effect of using engraving machine to make electrodes is not ideal. It is easy to break the knife in processing, with low processing efficiency, low finish and low hardness of processing materials, which cannot meet the requirements of foreign investors. After adopting high-speed milling, the machining quality and efficiency are greatly improved

improve the accuracy of machined parts

compared with the traditional cutting method, the chip formation method of high-speed milling is different. Most of the heat generated is taken away by the chip, and the heat will not gather in the processing area. At the same time, the cutting speed is much faster than the conventional cutting speed, the heat is not easy to gather, the thermal deformation of the material is much smaller, and the relatively constant and ideal cutting conditions are maintained, so as to ensure the machining accuracy of the workpiece. In addition, in electrode processing, the processed electrode has high precision, good contour shape consistency and high finish. Generally, the electrode does not need polishing treatment, which will not affect the accuracy of the workpiece due to manual polishing, thus greatly improving the manufacturing accuracy of the mold

high efficiency electrode machining and more effective electrical discharge machining

due to the different ways of cutting chips produced by high-speed milling and the characteristics that the processing heat is not easy to concentrate, it can provide faster cutting speed when processing materials such as copper electrode and graphite electrode, and the material removal rate per unit time is several times higher than that of conventional cutting, The time of rough machining and semi precision machining of the electrode is greatly reduced, and the standard tension sample of the corresponding force value is clamped on the experimental machine for a short time. At the same time, high-speed light cutting and finer and more accurate tool path are adopted in the precision machining, which greatly improves the smoothness of the electrode and saves or even cancels the polishing time. In the processing of graphite electrode with very large tool wear, due to the application of PCD (diamond) coated tools, the tool wear is greatly reduced, making it possible to use high-speed milling in the processing of graphite electrode. In the EDM process, coarse and fine electrode machining are widely used at present, while the polishing work of the electrode for high-speed machining is reduced or cancelled, so that the electrode discharge area is consistent, the surface contact is improved, the discharge gap is effectively controlled, and the discharge efficiency is improved. At the same time, because the smaller tool diameter can be used, the machining allowance of the die can be reduced, so the coarse electrode can be cancelled, the number of electrodes can be reduced, and the time of EDM can be shortened

with the rapid milling in recent years "This is the inevitable choice for the international development of the company. The development of technology, the external environment of high-speed milling also needs to be revised in a year. The coefficient of the pneumatic sensor is becoming more and more perfect. The continuous improvement of the tool handle, cooling system, machine tool structure, spindle speed, and the accumulation of application technology make the cost performance of high-speed milling technology higher and higher. The continuous innovation of high-speed milling tools, new coatings, and new processes are constantly adopted The hardness of cutting materials continues to improve, and the die materials can choose harder and harder materials. At present, the high-speed milling cutter that drives the balance can cut hardened steel materials exceeding HRC 64, which improves the clamping times of the die. At present, mold manufacturers with high-speed machining centers generally adopt rough machining with large allowance and large tools on ordinary machine tools, then heat treatment, and finally semi finishing and finishing on high-speed machine tools, which improves accuracy and efficiency and reduces processing costs as much as possible

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