Superior performance of the new micro end mill:
End mills with small diameters (ie micro end mills) have passed the test of industrial applications. However, different processing tasks have their own different characteristics. These different tasks and requirements raise many considerations for the choice of end mills. The micro end mill is an end mill that is manufactured according to the principle of proportional scaling and reduces the geometric parameters of the ordinary end mill. It does not guarantee the reliability of the production process. Frequent micro end mills only "cut" and not "cut", and there are not many chips. This is related to the misunderstanding of the relationship between the length of the micro end mill and the depth of the knife. It is precisely this misunderstanding that leads to the breakage of the micro end mill during processing.
(1) The design is more scientific and practical, the performance is good, and the cost is lower.
In this case, a new type of miniature end mill with a lower cost (Fig. 1a) has been developed. This design is characterized by the fact that the transition of the micro-milling cutter from the cone to the cutting point is an arc.
1) This hyperbolic transition tool bar avoids the contact between the tool and the workpiece during the cutting process, thereby reducing the friction load.
2) On the other hand, the circular shank cross section also has good elastic deformation properties, preventing stress cracks in the micro end mill shank. According to this method, each cutting edge participating in the cutting is subjected to the same cutting force. Sudden changes in cutting conditions can be compensated and balanced by the elongated elastic shank of the micro-milling cutter. Depending on the material being cut, the cutting part can have an optimum axial plunging depth, making it easy to remove all machining allowances at once.
(B), the geometric parameters are related to each other to meet the different technical requirements of the tool geometry, from the mechanical performance point of view also ensures the best stability.
The geometric parameters of the micro end mill are all interconnected. When a parameter of the tool changes, such as when the diameter of the end mill changes, other parameters also change accordingly. The relationship between the various parameters of the tool can be represented by a simple, patent-protected mathematical formula. This function satisfies the shaping of the tool geometry for different technical requirements and guarantees optimum stability from a mechanical performance point of view. In addition, according to this method, it is possible to achieve the expected targets of cutting parameters and strategic applications in the processing of micro end mills; and for users to complete unique processing tasks. These optimizations and options all contribute to the estimation of tool durability and cost savings by reducing tool consumption. The diameter of this new type of miniature end mill is mainly concentrated in 0.05~2mm. The effective tool length ranges from 0.1 to 20 mm; the relative length to diameter ratio l/D ranges from 2 to 10. Common micro end mills include miniature end mills, micro toroidal end mills and miniature arc end mills (Fig. 1b).
With today's grinding technology, the production and structural optimization of micro end mills can be done without difficulty. Some well-known tool manufacturers have verified the micro-end milling program introduced in this paper under industrial application conditions, and realized the optimization of tool geometry parameters according to industrial production tasks, and pushed it to the market.
(C), this micro-end milling cutter industrial application program has also received very good results in two aspects. On the one hand, compared with the traditional miniature end mills, the new end mills reduce the stress generated in the tool by 50% with the same cutting force; the tool deformation is reduced by 50%. On the other hand, cutting parameters such as cutting speed, feed rate and knife depth have been significantly improved.
Of course, the mechanical properties of this new type of micro end mill are limited. For example, the use of a tool with a length to diameter ratio of l/D > 10 for the complex machining of the quenched tool steel in the three-coordinate direction cannot be done simply by using a micro end mill, but it is not impossible. For example, a graphite electrode can be used for electrical discharge machining, and a graphite electrode can be processed using a micro end mill having a length to diameter ratio of 1/D>10, thereby indirectly producing such a complicated workpiece. In the EDM process using electrodes, the emergence of micro end mills can economically solve the problems encountered in production tasks.
(4) Tool steel capable of processing quenching hardness up to 62HRC:
In order to prove the superiority of using micro end mills, a machining test was carried out exclusively using tool steel with a quenching hardness of 62 HRC. It has long been impossible to machine steel of this hardness with a milling cutter. The cutting speed and feed per tooth of the hard steel using the new micro end mill are doubled compared to the lower hardness of the steel using the improved micro end mill. Milling time is reduced by 85% when performing a contour milling test with this new milling cutter. The optimized micro end mill has a 30% increase in tool life. All test tools were not broken after the test was completed. At the same time, the processing test of high alloy steel and electrode materials was completed. The smallest geometric profile size it processes is only a few hundredths of a millimeter.
(V), the practice of obtaining answers: the extraordinary technical test ended with a successful practice test, using the performance-optimized milling micro-milling cutter to complete the 3D contour milling of high-alloy steel workpieces. This technique is also suitable for processing electrodes of conventional materials. The impeller has an outer diameter of 4 mm, a width of 1.2 mm, and a blade length of 1 mm. The micro end mill used has a diameter of 0.5 mm, a cutting speed of 40 m/min, and a feed per tooth of 2 μm.
End mills with small diameters (ie micro end mills) have passed the test of industrial applications. However, different processing tasks have their own different characteristics. These different tasks and requirements raise many considerations for the choice of end mills. The micro end mill is an end mill that is manufactured according to the principle of proportional scaling and reduces the geometric parameters of the ordinary end mill. It does not guarantee the reliability of the production process. Frequent micro end mills only "cut" and not "cut", and there are not many chips. This is related to the misunderstanding of the relationship between the length of the micro end mill and the depth of the knife. It is precisely this misunderstanding that leads to the breakage of the micro end mill during processing.
(1) The design is more scientific and practical, the performance is good, and the cost is lower.
In this case, a new type of miniature end mill with a lower cost (Fig. 1a) has been developed. This design is characterized by the fact that the transition of the micro-milling cutter from the cone to the cutting point is an arc.
1) This hyperbolic transition tool bar avoids the contact between the tool and the workpiece during the cutting process, thereby reducing the friction load.
2) On the other hand, the circular shank cross section also has good elastic deformation properties, preventing stress cracks in the micro end mill shank. According to this method, each cutting edge participating in the cutting is subjected to the same cutting force. Sudden changes in cutting conditions can be compensated and balanced by the elongated elastic shank of the micro-milling cutter. Depending on the material being cut, the cutting part can have an optimum axial plunging depth, making it easy to remove all machining allowances at once.
(B), the geometric parameters are related to each other to meet the different technical requirements of the tool geometry, from the mechanical performance point of view also ensures the best stability.
The geometric parameters of the micro end mill are all interconnected. When a parameter of the tool changes, such as when the diameter of the end mill changes, other parameters also change accordingly. The relationship between the various parameters of the tool can be represented by a simple, patent-protected mathematical formula. This function satisfies the shaping of the tool geometry for different technical requirements and guarantees optimum stability from a mechanical performance point of view. In addition, according to this method, it is possible to achieve the expected targets of cutting parameters and strategic applications in the processing of micro end mills; and for users to complete unique processing tasks. These optimizations and options all contribute to the estimation of tool durability and cost savings by reducing tool consumption. The diameter of this new type of miniature end mill is mainly concentrated in 0.05~2mm. The effective tool length ranges from 0.1 to 20 mm; the relative length to diameter ratio l/D ranges from 2 to 10. Common micro end mills include miniature end mills, micro toroidal end mills and miniature arc end mills (Fig. 1b).
With today's grinding technology, the production and structural optimization of micro end mills can be done without difficulty. Some well-known tool manufacturers have verified the micro-end milling program introduced in this paper under industrial application conditions, and realized the optimization of tool geometry parameters according to industrial production tasks, and pushed it to the market.
(C), this micro-end milling cutter industrial application program has also received very good results in two aspects. On the one hand, compared with the traditional miniature end mills, the new end mills reduce the stress generated in the tool by 50% with the same cutting force; the tool deformation is reduced by 50%. On the other hand, cutting parameters such as cutting speed, feed rate and knife depth have been significantly improved.
Of course, the mechanical properties of this new type of micro end mill are limited. For example, the use of a tool with a length to diameter ratio of l/D > 10 for the complex machining of the quenched tool steel in the three-coordinate direction cannot be done simply by using a micro end mill, but it is not impossible. For example, a graphite electrode can be used for electrical discharge machining, and a graphite electrode can be processed using a micro end mill having a length to diameter ratio of 1/D>10, thereby indirectly producing such a complicated workpiece. In the EDM process using electrodes, the emergence of micro end mills can economically solve the problems encountered in production tasks.
(4) Tool steel capable of processing quenching hardness up to 62HRC:
In order to prove the superiority of using micro end mills, a machining test was carried out exclusively using tool steel with a quenching hardness of 62 HRC. It has long been impossible to machine steel of this hardness with a milling cutter. The cutting speed and feed per tooth of the hard steel using the new micro end mill are doubled compared to the lower hardness of the steel using the improved micro end mill. Milling time is reduced by 85% when performing a contour milling test with this new milling cutter. The optimized micro end mill has a 30% increase in tool life. All test tools were not broken after the test was completed. At the same time, the processing test of high alloy steel and electrode materials was completed. The smallest geometric profile size it processes is only a few hundredths of a millimeter.
(V), the practice of obtaining answers: the extraordinary technical test ended with a successful practice test, using the performance-optimized milling micro-milling cutter to complete the 3D contour milling of high-alloy steel workpieces. This technique is also suitable for processing electrodes of conventional materials. The impeller has an outer diameter of 4 mm, a width of 1.2 mm, and a blade length of 1 mm. The micro end mill used has a diameter of 0.5 mm, a cutting speed of 40 m/min, and a feed per tooth of 2 μm.
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