Mealing is also called a milling process, and is a processing method that cuts fixed work with a rotating tool. Generally, mechanical machines such as machining centers and milling boards are used for milling. This article explains the issues generated by milling processing and the points you want to keep in order to realize high -precision milling processing.
Milling processing is a method of performing the work on the work while rotating a cutter with multiple cuttings. The feature is that each cut blade drains the cuts, so the processing efficiency is very high. The most common milling processing method is the front shaving that cuts the work surface straight. Milling processing is an important part of the cutting process, and can use a milling board or a machining center to perform various shapes, such as plane, curved surfaces, groove processing to hole processing. As a result, tools such as milling and end mills can be installed and fixed materials can be processed. It is important to learn how to use it and use the milling process because it can be used by combining a milling board and a variety of tools. Issues generated by milling processing In the milling process, the processing of poor processing and tool life is an issue. It is also necessary to pay attention to uneven quality due to variations at the time of processing.
The occurrence of chattering may lead to deterioration of the finishing surface, as well as tools and machine damage. The vibration that occurs in the milling process can be categorized as "self -encouraging" and "forced chattering". Self -encouraging vibration is a vibration generated by the vibration generated by the change of cutting resistance during cutting. The forced vibration is generated by servo motors and external vibration of the machine machine itself.
In the milling process, a large load is applied to the cutting tool. Therefore, it is important to do a faster blade wear than other processing methods, and in the case of continuous processing, it is important to grasp the tool status. Keeping wearing tools will lead to damage to tools and reduced processing accuracy.
In the milling process with a lot of work setup, the quality of the quality is generated by variations in the work at the time of setup. In addition, cutting powder adheres to the jigs and holders that fix the work, which may cause a positional shift when installing the work may be reduced.
We will introduce measures for the assumed assumed tasks by meshing by tasks.
The cause of the chattering may be intertwined in complexes. Therefore, in order to suppress chattering, it is necessary to consider measures from various perspectives.
One of the factors that causes chattering is the cutting resistance. It is effective to adjust the cutting conditions such as the cut volume and sending speed to suppress the chattering. By reducing the transmission speed and cut amount during cutting, the cutting resistance can be reduced and the generation of chattering can be suppressed. The optimal cutting conditions vary depending on the shape, material, and the type of cutting tool, but it is important to adjust while balancing because the cut speed decreases.
In order to suppress vibration during the milling processing, the use of a short tool with a short protruding is ideal. It is also effective in suppressing chattering because the tool itself can be suppressed. In the case of a tool with a long protruding, it is necessary to be careful because the vibration is more likely to be amplified, and it is easy to generate chattering.
By reducing the number of blades that hits the work at the same time, it is possible to reduce the cutting resistance generated between the work and the tool. In addition, since the interval between blades and blades is widened, it can be expected to improve the emission of the powder. On the other hand, by reducing the number of simultaneous cutting blades, the balance efficiency and tool life decrease, so balance is important depending on the situation.
It is effective to shorten the protruding of tools to suppress vibration, but it may not be possible to shorten the protrusion due to the shape of the work and the approach. In such a case, you can suppress chattering by using a high rigidity holder. When cutting a high load, such as molding, it is also necessary to consider the rigidity around the main axis and the shank.
In order to improve the lifespan of cutting tools, the use of a tool with high abrasion -resistant coatings is given to the adoption of down cut, the intermittent processing, and the coating -resistant coating.
By adopting a "down cut" that makes the tool's rotation direction and the direction of the work the same, the length of the cutting can be substantially shortened. This reduces the burden on the edge of the blade, improving the life of the tool.
The processing status in which work and tools intermittently contact are called "intermittent processing". The intermittent cuts are applied to the cutting tools, so you can improve the life of the tool by avoiding intermittent processing and continuously processing.
In order to suppress the wear of cutting tools, it is effective to adopt a coding with high wear resistance. Even when cutting under the same conditions, it can improve the life of the tool by reducing the perfume per wear.
If the setting of the tools varies, the load on the tool may vary even if the load on the tool changes and the cutting conditions are the same. Especially in the case of a tools with a long protruding, the risk of vibration is likely to be amplified, and the quality of the product may vary. When the operator sets a tool, it may be said that the tool length variations occur in the tool length, resulting in variation in quality. By shortening the amount of tools as much as possible, giving instructions to the site so that the amount protruding amount for each process is uniform, etc., to improve the tool rigidity, to improve the tool rigidity, to improve cutting conditions and processing accuracy. I can expect to improve.
It is generally said that if the tool length is doubled, the rigidity will be 1/8. It is also important to clean it with air so that it does not bite into the jigs and holders. If the clamp is chewed, the tools will not be normally cramped and the quality of the product will be impaired during processing, and the rigidity of the tool will be reduced, so the life of the tool will be shorter. Be careful about this.
In the case of a milling process, it is important to use the end milled according to the cutting location. There are the following types of end mills that are often used.
Flat end mills are end -mills with a flat tip of the edge of the blade and highly versatile. We can handle a wide range of flat, side, step, groove processing.
Radias -end mills are characterized by a rounded end of the edge of the blade and is high. Good at curved surface processing and molding.
The ball end mill is used for molding and 5 -axis processing with less cutting resistance.
Raffing end mills are used for rough processing because they have good cut powder.
In this article, we explained the issues generated by the milling process and the points that you want to keep for high -precision milling processing. & nbsp; & nbsp; This is the basic processing processing of the cutting, but in order to achieve high -efficiency processing while suppressing the unevenness and quality unevenness, it is important to use tools and cutting conditions.
