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Easy milling of high hardness parts

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Update time : 2019-07-31 14:12:25
Machining hardened workpieces has always been a problem, but many visionary factories have found a solution. In fact, even in some mold cavity machining operations, some plants have been able to increase the speed by 4 to 5 times when machining steel workpieces with hardnesses up to RC60. Some factories have even found ways to mill high-hardness workpieces on conventional low-power machines using conventional end mills.

“The processing of high-hardness materials has always been a problem, and every factor has to be carefully considered when milling it,” says Bill Fiorenza, product manager at Ingersoll Tool Company. “And considering the economics of the entire process. At the time of tool life, the proportion of tool life is greater. Compared with the means of greatly increasing the feed rate, minimizing the downtime spent on tool change often saves more machining costs."

Increase the speed of machining mold parts by 5 times

A recent and successful example of a successful die-casting mold factory in Dallas, Grand Rapids, Michigan. Not surprisingly, the main task of the plant is to mold cavity milling of hardened molds and mold materials.

With a simple tool change, Datum can rough the mold material five times faster and completely eliminate the semi-roughing process (Figure 1). The standard tool they used previously was a traditional 0.5in 4-slot solid carbide round head slot milling cutter. Today they use a 2-slot indexable Ingersoll Chip-SurferTM high feed rate fillet blade cutter. The setup follows a modern “fast feed/shallow milling” strategy – 400ipm/0.020” DOC/3855 rpm. This feed rate is 10 times faster than before, and the number of downtimes due to tool wear is reduced; It takes place once every 15h, the replacement takes only a few seconds, and it can be replaced directly on the spindle. From the point of view of material removal, it has reached 25:1 in terms of downtime and tool inventory cost. Saving results.

The person who is most familiar with this process is Datum's process engineer John Smith: "The roughing accuracy is now so good that we can go straight into the finishing process. We not only achieve a 10 times higher feed rate during roughing. And it can also achieve a wider milling range, reducing the chipping time from two aspects."

The Chip-Surfer tool is essentially an alloy steel rod that can accommodate a variety of interchangeable carbide tips. Datum chose a high-feeding cutter head with 2 milling slots and a cross-section in the shape of a rounded corner. This design allows the tip movement to be more aggressive when milling the surface of the material near the pitch radius, allowing the tool to move more at the optimum milling speed. In contrast, a carbide-shaped round-face slot milling cutter with a spherical geometry means that the optimum milling speed can only be achieved in the midline section.

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