In the forming process, the order of movement of the milling tool is as follows: fast forward to the safe distance - work forward to the cutting depth - tool return. SPIRON gear milling cutter process for dry cutting, so the cutting heat generated by the most will be take away by scrap iron, scrap iron in blue, for the best cutting state, so the cutting parameter setting as basic principles.

The cutting line speed of the carbide gear cutting tool is set at 180-220m/min, which is the most suitable. The constant line speed cutting method is usually adopted to reduce tool wear. The selection of cutting parameters is based on: in the initial stage of cutting, the cutting force is not too large, so the feed speed can be increased appropriately, since only the tip part participates in cutting. At the end of the cutting process, most of the cutting edges of the teeth will be involved in cutting, so the feed speed should be reduced. In order to improve the roughness of the tooth surface, the tool needs to stay at the final dimension for a certain time when the tooth depth is reached.

Unlike displayed, when generating method processing tool motion sequence is that fast forward to a safe distance from - to the cutting depth, cutting tool back in work - cutting tool cuts - cradle swing again gradually return finished cutting - tools.

Generative cutting, the cutting depth of the allowance allocation problem: due to the generating method processing, tooling need a second cut, therefore involve generating surplus allocation problem, such as the distribution of allowance is too small, will cause the generative process, tool vibration, tooth surface roughness; If the residual amount distribution is too large, the tool will be under too much force and the tool life will be affected. After a lot of trial and error in the field, the optimal JW machining allowance is 0.3-0.5mm. Generative cutting stage cutting parameter selection: when carries on the generative cutting, generally starting gear big end cutting, cutting allowance is bigger, so at this stage of the feeding should be appropriate, tooth width as generative approaches to the end, because the machining allowance is very small, may be appropriately increased feeding.

Tool wear judgment basis, according to the scrap color judgment

If the tool is in good condition, the iron chips shall be dark blue to light blue, and the surface of the iron chips shall be smooth and smooth. If the cutting tool is in poor condition, or after wear, the cutting iron chip is generally yellow to white, and the iron chip surface is rough and curly, indicating that the cutting heat has not been fully taken away.

If carbide gear cutting tool is in good condition, when cutting, the machine load is stable and the fluctuation is small, the maximum is about 20%. On the contrary, the load of machine tool fluctuates greatly, sometimes reaching more than 30%.

When the cutter is in good condition, the tooth surface is smooth and the burrs are small. When the cutter is in poor condition, the tooth surface is rough and the side burr is large.

Before using the new coated blade, the cutting edge is complete and sharp, and the overall color of the coating is grey and black. After wear, the tool cutting edge coating part has worn, the cutting edge is white, there are some serrated or even broken edges.

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Cemented carbide circular blade, called "wafer", is one of the series of hard alloy materials. It is usually used to make hard alloy blades and hard alloy tools, such as hard alloy woodworking tools, carbide cutting machine blades, hard alloy V-CUT knives, hard alloy cutting tools, hard alloy paper cutting knives, hard alloy cutting tools, hard alloy cutting tools, hard alloy cutting tools, and hard alloy cutting tools. Quality alloy hob, carbide circular knife, carbide milling cutter, carbide saw blade, cemented carbide split knife etc. Its application field involves various fields of national production, such as special cutting tools in the electronic industry, special cutting tools in woodworking furniture industry, special cutting tools in hardware machinery processing industry, and the characteristics of hard alloy wafers that are also resistant to corrosion and acid alkali and are not rusty by the food processing industry. With cutting tools, in short, the application range of cemented carbide wafers is very extensive. It is a good assistant material for people's production and processing.

If a shoulder milling cutter is used for rough milling of the cavity, a large amount of step cutting allowance must be removed in semi finishing. This will change the cutting force and make the tool bend. As a result, uneven machining allowance is left to finish machining, thus affecting the geometric accuracy of the die. If the blade tip milling cutter with a weak tip is used (with a triangular blade), it will produce an unpredictable cutting effect. The triangle or diamond blade can also produce greater radial cutting force, and because the number of cutting blades is less, they are poor economiccutting tools.

On the other hand, the circular blade can be milled in all kinds of materials and in all directions. If it is used, the transition between the adjacent tool paths is smooth and a smaller and more uniform machining allowance can be left for semi finishing. One of the characteristics of a circular blade is that the chip thickness they produce is variable. This enables them to use higher feed rates than most other blades. The main deflection angle of the circular blade changes from almost zero (very shallow cutting) to 90 degrees, and the cutting effect is very smooth. At the maximum depth of cutting, the main deflection angle is 45 degrees. When the straight wall profile is cut along the outer circle, the main deflection angle is 90 degrees. This also explains why the strength of the circular blade tool is large -- the cutting load increases gradually. Rough and semi rough machining should always be the first choice for round blade milling cutters, such as CoroMill 200 (see mold manufacturing sample C-1102:1). In 5 axis cutting, the circular blade is very suitable, especially without any restrictions.

By using good programming, the circular blade milling cutter can largely replace the ball end milling cutter. The small circular blade with small pulsation is combined with the fine grinding, positive rake and light cutting groove. It can also be used for semi finishing and some finishing.

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Waste powder is can't use at the scene of powder, in large (small) cyclone separation system of waste powder inside bucket of powder, the powder particle size is relatively small, charging effect is bad, it's hard to spray on the workpiece. We know that powder coatings have high production efficiency, excellent film coating performance, good ecological environment protection and outstanding economy. In the production, equipment manufacturers through the improvement of electrostatic equipment spray gun and equipment technology to improve the dead corner powder rate. There are many factors influencing the powder rate on the dead corner of powder coatings, which can be divided into external factors and internal factors. External factors include the elbow size and shape of the coated workpiece, customer powder spraying system, powder spraying construction personnel, etc., powder formulation adjustment and operational factors in the spraying process, which are internal factors.

The scrap rate is the percentage of waste powder = the percentage of waste powder/total used component.

What factors will affect the waste powder rate?

1. Particle size ratio of new powder

2. Air injection ratio

3. Frequency of color change

4. Powder rate

5. Separation efficiency of cyclone device

6. Integrity of the system

7. The primary qualification rate of spraying products is also a factor to reduce the waste powder

The particle size ratio of the new powder is determined by the powder factory. The powder factory needs to provide the particle size distribution map of the new powder to minimize the proportion of the fine powder.

Reduce the proportion of air blast, because when air blast is 0% powder rate, the powder is separated by cyclone devicewhile powder sprayingprocessing. The method is to change the hanging mode or increase the clearance automatic control system.

Every change of color will lose 10 kilograms of powder, reasonable production plan, can reduce a change of color, can reduce more than 10 kilograms of waste powder!

Increase the powder powder powder rate, also can reduce the waste powder. The powder rate is related to the electrostatic system of spray gun and the good or bad grounding of workpiece. The separation efficiency of cyclone devices is determined by the equipment manufacturer. High separation rate will reduce the amount of waste powder. The integrity of the system is also an important factor affecting the rate of waste powder. Timely maintenance of the system is also important in spraying! Increasing the qualified rate of spray products can reduce the amount of recycled powder, which can also reduce the proportion of waste powder.

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The heat treatment method used in domestic carbide saw blades is generally the salt bath method. After the heat treatment, the oxidation layer is thicker and the deformation of the saw blade is large. When the surface of the saw blade is taper, the oxide layer is not completely worn to make the saw blade undurable. The hardness of ordinary quenching is not good. Sometimes the hardness of the finished product is low, and it is not durable. Sometimes the toughness is low and the blade is easy to explode. The overseas saw blade quenching is treated by vacuum treatment and has the function of preventing oxidation. After quenching, the deformation of the saw blade is small, the difficulty of correcting the stress is reduced, and the saw blade has a small deflection value. According to the incomplete data, the deformation of the vacuum heat treatment is less than half of the ordinary quenching. The stability and repeatability of the vacuum heat treatment are good, and the quality fluctuation of the cutting tool is avoided by the conventional heat treatment. The high speed steel saw blade in vacuum heat treatment can obviously improve the toughness and fatigue strength of the cutting tool, so the saw blade is not easily detonated when cutting fast feed. The surface hardness error of the saws is controlled within one degree, which lays a solid foundation for the performance of the cutting process.

An important index affecting the effect of high-speed saw blade is the geometric taper design of the saw blade. The grinding taper of the saw blade in China is used for the grinding equipment used in the lathe modification. Usually the saw blade is erected, then the single surface is worn and then processed on the other side according to the experience. This way can not guarantee the consistency of the two sides of the saw blade, thus increasing the friction coefficient and cutting resistance of the saw blade, and affecting the cutting life. The special equipment used in foreign countries is made of special equipment. The saw blade is used for flat processing. Through the control system, the taper grinding operation of the saw blade will be operated automatically until it is completed. It can fully guarantee the consistency of the two tapers, thus ensuring the low friction coefficient and cutting resistance of the saw blade, which is beneficial to the cuttings and obviously improves the service life of the saw blade. And cut the verticality.

The aluminum alloy saw blade is used for the aluminum alloy material, sawing, milling, and cutting the groove. In the process of processing, it is in the polishing liquid rich in abrasive, and can be pressed on the workpiece. It can rotate at high speed.

1. It is necessary to finish polishing and polishing under light pressure, especially when polishing pre hard steel and fine grinding paste. When polishing with #8000 grinding paste, the load is 100~200g/cm2, but it is difficult to keep the precision of the load.

2. When the polishing process is stopped, it is very important to make sure that the workpiece is clean and carefully removed from all abrasive and lubricants. Then a layer of mould antirust coating should be sprayed on the surface.

3, each polishing time should not be too long, the shorter the time, the better the function. If the polishing process is too long, it will form "orange peel" and "pitting corrosion".

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"It is not only feasible to imagine the processing of nickel - chromium alloy 718 and other high temperature alloys (HRSAs) at the speed of processing aluminum," said Melissa Singher, a senior product engineer at the U. S.. The secret lies in the SX9 ceramic end mills produced by the cutting tool manufacturer.

Singher said: "in the use of SX9 mills to process superalloys (such as Inco 718 and 625), it is suggested that the speed is 2000 to 3000 SFM (surface feed / minute), with a minimum speed of about 1000 SFM. For example, in general, the minimum speed of a 0.5 inch vertical milling cutter is 8000r/min. To obtain the best performance, the spindle speed should be within the range of 15000 to 20000r/min. The feed rate is usually 0.0011 to 0.0013 IPT (inch / every blade), and the feed speed should exceed 100 ipm/min (inch / minute) when the 4 edge end milling cutter is used for 20000r/min cutting.

Singher says that a large number of spatters with spark chips will be quickly ignited, and the cutters will quickly prepare for the chip recycling, which is a very effective metal cutting process. It is worth noting that under proper machining technology, the working life of the tool can be as long as 10-25min. Singher explains that SX9 is a kind of SiAlON or silicon aluminum nitride ceramics, which ingeniously combines the strength of silicon nitride with the heat resistance and wear resistance of alumina. It is reported that the cutting edge design can withstand the extreme heat and pressure generated by high-speed machining of HRSA.

Singher added that working hardening is a common phenomenon at such a high cutting speed. This is also the reason why the end mills are mainly used for rough machining. Therefore, a cemented carbide end mill with a diameter of at least 0.3 cm (0.012 inches) is usually required for finishing. Here are some basic rules of thumb for SiAlON end mills.

Because of the high temperature, the continuous tool path can reduce the thermal shock of the tool.

When machining core, the inclination angle of 1.5 degree and 50% of conventional feed speed should be used.

Ceramic end mills are not suitable for machining titanium materials because the heat generated during processing will produce adverse reactions to the material.

Use the 6 edge end mill instead of the 4 edge milling cutter as far as possible to maximize productivity.

In addition, high speed and high balance hydraulic or heat shrinkable chuck or shaft should be selected as far as possible. No cutting fluid is used, instead of direct injection of a chuck with a strong convective air, which can prevent the expansion of a large amount of cutting heat produced during the process.

Finally, although the price of the ceramic cutter is much higher than that of the high quality hard alloy, the higher productivity in the use of the ceramic end mills is easy to balance the cost increase caused by the price.

Singher said: "because of the intense competition atmosphere in the engine parts industry, we have seen that the first and two tier sub contractors are very interested in this product. These companies really see their potential productivity of 15-40 times higher than that of carbide end mills, thus greatly reducing the manufacturing time of complex HRSA parts.

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