Tool folding is a phenomenon in which the load on the tools being processed is more than a certain level and the tools break. Tools during processing will not only occur in processing and damage to equipment, but also lead to major opportunity losses, such as the production does not progress. This article explains the causes of tools during cutting and effective measures.
If a tool fold occurs during the cutting of the work, it will not only lead to poor product, but also affects post -processing such as tool replacement. In addition, the larger the tool diameter, the greater the damage to the machine when it is folded, so it is necessary to prevent it. Cutting tools often occur in the following cases: If the tools and cut powder are entangled If the cutting resistance exceeds the allowable value of the tool If the tool is swinging
In situations where cutting powder is difficult to discharge, such as hole processing or groove processing, cutting powder may be entangled with the tool. If the cut powder is entangled, the load on the tool will be larger than usual, and the tool will be broken at a certain timing and the tool will be broken.
Each tool has a tolerant cutting resistance value, and its value depends on the processing status of the same tool. A tool folding is generated by exceeding the tolerated resistance value during processing. In particular, if there is a chipping or an unnoticed level minor chip, the tolerance resistance is lower than usual, so that tools are more likely to occur.
If the appropriate tool steps are not removed, swing may occur during rotation and the tool may be broken. For example, if the tool axis is attached in a state of shifting to the rotating culprit, the load is applied from the direction that does not usually apply, making it easier for the tool to be broken.
The tasks generated by the tool damage include an increase in the number of man -hours of the post -process and the generation of waste production time.
If the tool is broken, the processed work will not be used as a product and will be destroyed. In addition, the operating rate deteriorates due to various post -process work, such as inspection of equipment, replacement of tools, and review of production plan, such as equipment inspections for equipment and tools, and tools for replacement tools. Will be invited.
In unmanned operation, if you continue to process without noticing the damage to tools, you will produce a large amount of defective products, and the time spent on production will be wasted. Depending on the process, the work processed before the tool is damaged may be significantly reduced, such as requiring a full number of tests.
There are various factors in which tools occur. It is not easy to clarify how the load has accumulated, even after temporary load. If you do not know the progress of the load, you will not be able to take fundamental measures.
The following measures to prevent tool damage are as follows. It is explained in measures by selecting tools and measures by processing conditions.
There are the following measures to prevent tools preventing tools from selecting tools.
The tools are applied to the tools because the cut powder is entangled. Therefore, it is effective to adopt a chip breaker with a function to divide the cut powder finely. If cut powder is divided into small division, it will not be entangled with the tool and will not cause unexpected loads, making it less likely to be damaged.
High -precision coolant supply is also effective as a means of removing cut powder. If you select a tool that can be supplied with a coolant on the processing surface, the effects of the powder can be minimized. By cooling the processing surface, chipping that leads to tool fold can be suppressed.
In order to suppress the swing of tools, it is important to select a holder to fix the tool. The holder has a difference in how to join the tools, such as a collet chuck, a milling chuck, and a hydraulic chuck. Holders, which have various types, have compatibility and standards with tools, so it is important to select a combination that can improve processing accuracy.
Countermeasures based on the processing conditions at the time of cutting include the adoption of a path that takes into account the cut -off emissions and the condition setting to lower the load during cutting.
It is effective to set processing paths such as step sending in consideration of the discharge of cutting powder, so that the cut powder is not clogged. You can also discharge cutting powder by using "swinging cutting", which divides the cut powder.
In order to reduce the cutting load on tools during cutting, it is also effective to reduce the rotation speed, sending speed, and cut amount of the main axis. Depending on the combination of tools, processing work, processing paths, etc., it is necessary to adjust the conditions while checking the effect, as the cutting conditions are increased.
It is necessary to use a dedicated system, but monitoring the processing process at the time of cutting is also effective. The following measures are:
It is possible to check the load on the tools in the processing process during the cutting. When visualizing the processing load such as current value and sound waves, the data to be input differs for each system, but the processing load on the tools calculated based on these data is based on the indigo work that prevents it. It will be possible. You can take measures such as stopping the device by triggering the stage that has reached a certain level or the abnormal value detection.
As described above, there are various causes of tool damage. By monitoring the processing process, it is possible to confirm whether the cause of the tool folding is due to the wear of the cutting tool or due to sudden events. is. If the cause is identified, it will be possible to take appropriate measures and prevent the dark clouds prevent the tool set life.
In this article, we explained the causes of tools that occur during cutting and effective measures. It is not easy to identify the cause of the tool damage. It is a good idea to prepare a countermeasure in advance so that measures that match the situation can be selected quickly.
