High-speed machining of micro tools
Micro-tools refer to milling cutters. The diameter of the drill does not exceed 0.25 inches (6.35 mm). The high-speed machine does not have a clear definition of absolute parameter parameters, but the more practical definition means that the high-speed spindle is required to be very complicated or fine. Machining.
The spindle speed of the machine tool exceeds 25,000 rpm.
As
the manufacturing industry moves toward miniaturization, product sizes are
declining and varieties are becoming more and more abundant. Therefore, the use
of micro-tools is becoming more and more common. But the efficient and
economical use of these small tools requires both the use of specially designed
equipment and the willingness to move from conventional machining methods to
new tools. This is mainly due to the fact that the spindle of a conventional
CNC machine cannot meet the requirements of high-speed machining of
small-diameter tools. Even if speed requirements are met, the spindle will be
overloaded for a long period of time and add undue load to the equipment. For
example, a tool having a diameter of fewer than 0.5 inches (12.7 mm) runs at a
speed lower than or equal to 1000 rpm in a conventional CNC machining center,
resulting in improper feed rate, broken tool, and the like. Often, people
attribute tool breaks to operator errors, improper machining parameters, or
worse reasons simply because of the small tool relationship. The fact is that
the traditional machine tool spindle load and cutting force are large, and the
high speed required, the chip is effectively discharged from the cutting
groove.
Three
prior art
The
best way to perform efficient machining with small tools involves three levels
of the process. These three interrelated elements include high speed machining
technology, optimized micro tool design, and low viscosity coolant.
◆High-speed
processing technology:
The
smaller the tool, the more efficient it is to machine high-quality parts and
avoid tool breakage. High-frequency spindles with speeds up to 6000 rpm are
ideal for milling, drilling, tapping and engraving with micro-tools.
This
technology uses high speed, small cutting steps, but significantly improved
feed rate. For example, pass your hand through the burning candle. If your hand
moves too slowly, it will leave enough time for the flame to cause damage, but
if your hand passes through the flame very quickly, there is no time for the
flame. To hurt your skin. The same principle applies to the high speed
machining of micro tools. With a rapid movement, there is not enough time for
the heat to act on the part, causing problems. During machining, the tool
continuously cuts the chips from the workpiece, producing about 40% of the heat
from the friction on both sides of the tool and 20% from the deformation
(bending) of the chips. Therefore, approximately 60% of the heat is
concentrated in the chips. High-speed machining strives to reduce heat in the
chips and achieve clean cutting. Improving the quality of the process requires
better cooling of the tool, reduced cutting forces, and low vibration. The high
speed spindle reduces the chips to less than 0.005 inches (0.13 mm). This small
chip load greatly reduces the friction between the tool and the material. The
result of high-speed 1 low cutting force is reduced heat generation and reduced
tool deflection. The machine can process thinner-walled workpieces, resulting
in lower heat generation, excellent surface and edge quality, and higher
precision. As a result, the workpiece is easily clamped due to the low cutting
force. Because it is possible to use a modular vacuum table that is easier to
set up, it is convenient to change batches. (especially thin flat plates plus
[materials, even more so.)
◆ Optimize
tool design:
Changing
large diameter tools to small geometries produces unacceptable feed rates and
surface finishes. When the tool diameter becomes smaller and the spindle speed
increases, the requirements of Knife County should be changed. The traditional
use of inserting J-pieces is no longer suitable for machining with micro-tools.
This is mainly due to the increase in speed rather than the diameter. The
increase in speed requires a better combination of the tool and the space left
for the chips, ensuring that the chips can be discharged and prevented from
accumulating. Effective machining with small tools requires special tools for
high speed machining to optimize the tool. The right micro-tool geometry,
combined with a high-speed spindle and ideal coolant, completely eliminates the
need for subsequent deburring and grease removal.
◆Low
viscosity coolant:
High-speed
machining essentially reduces heat build-up and typically requires coolant to
cool fast-moving micro-tools. Companies that specialize in high-speed machining
with small tools know that coolants used in traditional CNC equipment are not
ideal in this new situation, which is an excellent example of the need to jump
out of the existing thinking-frame when using high-speed machining.
Small
tools with complex geometries and extremely high rotational speeds require coolants
and lubricants with lower viscosity than water. The low viscosity is required
because the coolant needs to reach the edge of the tool even at high spindle
speeds. Emulsions have a higher viscosity than water, so they are not effective
lubricants for high speed machining with micro tools. However, some coolant
micro-injection systems can use ethanol, which is commonly produced in sugar
fermentation processes and typically has a lower viscosity than water. Ethanol
has a low evaporation point and can be used as a very effective cooling and
lubricant for efficient processing. Moreover, conventional coolants are all
petroleum-based, and the waste liquid needs to be properly treated, and the
ethanol only needs to be volatilized, thereby saving the cost associated with
waste disposal. Furthermore, ethanol does not leave residual material on the
processed product, thereby eliminating costly degreasing work.
Machine
power
Using
a micro tool is not as easy as finding a fixture to clamp a small tool onto a
conventional CNO machine 40 taper spindle. Because the spindle is designed to
accommodate large tools such as 3-inch fly knives for deep cutting of
high-density substrates. In that case, the cutting will form a large moment and
the cutting force, and the small tool will be easily broken, which will reduce
the production efficiency and increase the cost in the long run. At this point,
the operator's only option is to reduce the speed and feed rate to the creep
state, which is very inefficient because the machining cycle is too long. “A
vivid, perhaps somewhat funny, metaphor is to compare a semi-powered double-row
minivan with a sports car. The reality is that you don’t compare the two or
compare them. Why? Because of the truck design, It is to have the power and
strength to pull or drag heavy goods, and the sports car is designed for speed
and mobility.
In
essence, traditional CNC manufacturers who boast the ability to run
micro-tools, and car manufacturers put spoilers and racing stripes on bulky
SUVs, and then claim that the car has the same performance as Porsche. Just as
you can't expect to install spoiler and racing stripes on the SUV, it can
behave like a sports car. You can't load a high-speed spindle on a cumbersome
traditional machine, and then expect it to be highly efficient and high-speed
machining with micro tools. same. When designing a machine, you can choose one
of two directions. That is, you can design the machine to be a large motor,
high-speed, low-cutting spindle for micro-tools, or to create a spindle with a
lightweight, high speed, and low cutting force dedicated to micro-tools. Of
course, both types of machine tools can be used for a variety of purposes, such
as milling, drilling, tapping, slotting, etc. But the so-called versatility is
also limited to this. Ultimately, if processing efficiency and quality are
important and both large and small parts need to be machined, the result is
that two different machines need to be installed in the same shop. Although it
may seem like a repetitive investment in equipment, the cost can quickly be
achieved through efficiency and versatility associated with return on
investment (ROI).
Recycled.
You can produce parts better, faster, and more economically.
solution
If high-speed machining centers are considered separately, the best way to machine with micro-tools is to use equipment that combines the above advantages of high-speed machining technology, optimized micro-tool design, and low-viscosity coolant. If you combine the three factors, you can bring unimaginable processing speed and product quality. However, the advantages are not limited to this, and the process can completely eliminate secondary work such as deburring and degreasing. Here, two examples of high-speed machining can be cited, as Datron machines can do. First: a 0.25-inch (6.35 mm) single-edged knife, cutting 6061 aluminum, cutting depth 1/8 inch, processing speed 45000 rpm, cooling with ethanol, feed rate 250" / min. Second, with 1 / 8 "Double-blade high-speed cutting tool (HSC+), processing 6061 aluminum plate with low helix angle, depth 1/8", processing speed 50000 rpm, ethanol cooling, feed rate 200" / min. High-speed machining has certain rules to follow. First, avoid overheating of the spindle, because it will aggravate wear and damage, and greatly reduce the service life of the spindle; "half the maximum diameter of the tool in the Z-axis direction: with a smaller step, Higher feed rate: Finally, move quickly to dissipate the heat from the chips.
In
conclusion
In short, use the right tools to get the right job. The golfer will not use the No. 1 woods on the greens and will not use the putters to kick the ball. Conventional machine tools have low speeds and high spindle cutting forces, which cannot meet the requirements for efficient cutting of small tools. Only high-speed machine tools for micro-tool machining can meet the high-efficiency and high-quality machining of the most complex and small parts according to specific needs. High-speed machining with micro-tools has the advantages of low cutting force, less tool breakage, less heat accumulation, high surface finish, no need for deburring and degreasing, and low tool vibration. Spindles with speeds between 25,000 rpm and 60000 rpm, with smaller tools, resulting in better part quality and shorter machining times. Datron's machine range offers these advantages, giving users the benefits and helping manufacturers improve efficiency and product quality when machining small parts with micro tools. Our machine tools are typically 40" x 27" x 8", and are available in other sizes.
Deshengrui Machinery is a professional CNC manufacturing and sheet metal fabrication company, including CNC machining services, CNC turning service, CNC milling services, CNC drilling services, laser cutting services, stamping services, die casting service, iron casting service and steel forging service.