Application of coating in shaft machining
Core Tip: Changing machining tasks are constantly placing new demands on single or small batch parts manufacturers. If you want to gain an edge in the fierce competition, you must use efficient milling tools, first
Changing machining tasks are constantly placing new demands on single or small batch parts manufacturers. If you want to gain an edge in the fierce competition, you must use efficient milling tools. The first task is to meet the technical and economic requirements.
The competition between most tool and mold manufacturers is reflected in the services they can provide: such as the size, material, processing and precision of the workpieces that can be machined. Individualized strategies can improve time and cost pressures and provide advice on process optimization to service.
One of the difficulties is productivity, which is also a major challenge for most processing companies. To optimize costing and increase competitiveness, tool manufacturer Paul Horn has developed a range of products for different applications and materials, including DS series full carbide milling cutters, DA series end mills and spiral end mills. DM series combination milling cutter.
In general, the user will select the tool according to the product manual or according to special specifications. As a result, the versatile tool and tooling industry requires high flexibility and short lead times. In addition, Horn has been engaged in tool development and analysis of numerous application cases for many years, which has enabled them to have strong professional capabilities and to solve complex milling problems.
A medical device manufacturer hopes to simplify the casting process of a cylindrical support by providing a funnel-shaped gate. WF Fottner, from Moessingen near Tuebinen, took on this task, using four templates to make the required two-piece injection casting mold.
The goal is to process 2 million times
The mould has an edge length of 500 mm and a special profile according to the user's requirements, with the aim of achieving 2 million machining – the company has designed a special mould for this and found a special process for the tool. This collaboration with Tuebingen's tool manufacturers not only shortens the geographical distance, but more importantly meets the requirements of tool type, efficiency, precision and economy.
The first task is to rough the template of the closed edge. The material is hot work die steel 1.2343ESU. The specific processing parameters are as follows: the angle cutter with DM series has a diameter of 12 mm and the cutting head radius is 2 mm. Inspection control is performed using a 0.2 mm gauge block. This process features patented components for connecting the shank and the blade for diameters ranging from 8 to 12 mm.
Since the shank is used as a bracket for blades of various diameters, the fit between them needs to be very precise, so it is necessary to select the tool as little as possible in accordance with the cutting parameters for economical machining.
Carbide shanks have a wide range of lengths and a collapsible construction. The use of a holder with a length of up to 140 mm allows access to the inside of the cavity and achieves high radial accuracy.
Due to the delivery period and the ability to make better use of the machining center, two brass electrodes can be placed next to the machining center template for processing additional injection casting molds. Although the milling parameters of the two are different (different from the template, the brass electrode requires a humid environment), the CNC programming process can be made relatively simple because the DM series milling cutter can be used alone. The brass milling cutters on the catalogue can have 2, 3 or 4 cutting edges, respectively, and the diameter of the cutting circumference ranges from 0.3 to 12 mm. The recommended machining parameters for roughing with electrodes are: ring and full radius structures with 2 to 4 blades. For semi-finishing and finishing of wire molds, double-edged micro-milling cutters with a diameter of 0.3 to 2 mm can be used.
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