What tools are mainly used in these different processes?:-?
Rough process: round blade cutter, ball end mill, Large corner radius of the milling cutter.
Semi-finishing process: round blade cutter (diameter range is between 10-25 mm), ball end mill.
Finishing process: round blade cutter, ball end mill.
Residual milling process: round blade cutter, ball end mill, vertical mill.
It is very important to optimize the cutting process by choosing professional tool size, groove and trademark portfolio, as well as the cutting parameters and suitable milling strategies.
Is there a most important factor in cutting process?:-?
The most important goal in cutting process is to create uniform distributed working allowance for each tool in each process. This means that you must use the tools of different diameters (from big to small), especially in rough process and semi-finishing process. Any time, the main criterion should be tool is similar with the final shape of mould as far as possible in each process.
Supply uniform distributed working allowance for each tool ensures a stable and high productivity and safe cutting process. When ap/ae (axial cutting depth / radial cutting depth) is constant, the cutting speed and feed rates can be kept in a higher level. In this way, the mechanical action on the cutting edge and work load will change little, so that the heat and fatigue are also less, these improves the tool life. If the after process is semi-finishing, especially all the finishing process, unmanned or half unmanned process can be operated. A constant material working allowance is also a basic standard in the high speed cutting application.
The other beneficial effect of working allowance is having a small negative impact on the machine tool-guide, ball screw and main shaft bearing.
Why the round blade cutter is usually the first choice in mould rough process?:-?
If you use a square shoulder milling cutter for rough milling of cavity, it will remove a large number of the step chipping allowance in semi-finishing. This will change the cutting force, and bend the tool. The result is leaving uneven machining allowance for finishing, and affecting the geometry accuracy of the mould. If you use a square shoulder milling cutter (with triangular blade) which has weak knifepoint strength, it will produce unpredictable cutting effect.
Triangular or diamond blade will also have greater radial cutting force, and because of the small number of blade cutting edge, they are the rough process tool with poor economic benefits.
On the other hand, round blade cutter can mill in a variety of materials and all directions, if you use it, the transition between adjacent tool path will more smooth, and you can also leave a smaller and more uniform machining allowance for semi-finishing process. One of the characteristics of round blade cutter is the variable cutting thickness. It provides a higher feed rate than many other blades. The main tool cutting edge angle of round blade cutter can change from nearly 0 (very shallow cutting) to 90 degrees, the cutting action is very stable. In the maximum cutting depth, the main tool cutting edge angle is 45 degrees, when profiling along cylindrical straight wall, the main tool cutting edge angle is 90 degrees. This also explains why round blade cutter has a large strength-cutting load is gradually increasing.
Through the use of good programming, round blade cutter can replace ball end mill in a large extent. Round blade cutter which has small beating amount cooperate with positive rake angle and light cutting groove, can be used for semi-finishing and some finishing.
Rough process: round blade cutter, ball end mill, Large corner radius of the milling cutter.
Semi-finishing process: round blade cutter (diameter range is between 10-25 mm), ball end mill.
Finishing process: round blade cutter, ball end mill.
Residual milling process: round blade cutter, ball end mill, vertical mill.
It is very important to optimize the cutting process by choosing professional tool size, groove and trademark portfolio, as well as the cutting parameters and suitable milling strategies.
Is there a most important factor in cutting process?:-?
The most important goal in cutting process is to create uniform distributed working allowance for each tool in each process. This means that you must use the tools of different diameters (from big to small), especially in rough process and semi-finishing process. Any time, the main criterion should be tool is similar with the final shape of mould as far as possible in each process.
Supply uniform distributed working allowance for each tool ensures a stable and high productivity and safe cutting process. When ap/ae (axial cutting depth / radial cutting depth) is constant, the cutting speed and feed rates can be kept in a higher level. In this way, the mechanical action on the cutting edge and work load will change little, so that the heat and fatigue are also less, these improves the tool life. If the after process is semi-finishing, especially all the finishing process, unmanned or half unmanned process can be operated. A constant material working allowance is also a basic standard in the high speed cutting application.
The other beneficial effect of working allowance is having a small negative impact on the machine tool-guide, ball screw and main shaft bearing.
Why the round blade cutter is usually the first choice in mould rough process?:-?
If you use a square shoulder milling cutter for rough milling of cavity, it will remove a large number of the step chipping allowance in semi-finishing. This will change the cutting force, and bend the tool. The result is leaving uneven machining allowance for finishing, and affecting the geometry accuracy of the mould. If you use a square shoulder milling cutter (with triangular blade) which has weak knifepoint strength, it will produce unpredictable cutting effect.
Triangular or diamond blade will also have greater radial cutting force, and because of the small number of blade cutting edge, they are the rough process tool with poor economic benefits.
On the other hand, round blade cutter can mill in a variety of materials and all directions, if you use it, the transition between adjacent tool path will more smooth, and you can also leave a smaller and more uniform machining allowance for semi-finishing process. One of the characteristics of round blade cutter is the variable cutting thickness. It provides a higher feed rate than many other blades. The main tool cutting edge angle of round blade cutter can change from nearly 0 (very shallow cutting) to 90 degrees, the cutting action is very stable. In the maximum cutting depth, the main tool cutting edge angle is 45 degrees, when profiling along cylindrical straight wall, the main tool cutting edge angle is 90 degrees. This also explains why round blade cutter has a large strength-cutting load is gradually increasing.
Through the use of good programming, round blade cutter can replace ball end mill in a large extent. Round blade cutter which has small beating amount cooperate with positive rake angle and light cutting groove, can be used for semi-finishing and some finishing.
