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cnc machining center CUTTING TOOLS KNOWLEDGE

KYLT Precision CNC Machining — Mon, 28 Oct 2019 00:56:52 +0000

In CNC milling or lathing, Different shapes need use different cutting tools. This article stated some knowledge of cutter in CNC machining.

Aluminum Fast Prototypes by CNC milling

Basic classification of cutting tools

According to the end geometry:

Flat end milling cutter
Flat bottom R angle end milling cutter
Ball end milling cutter
Indexable inlaid end milling cutter

CNC machine cutters

Basic geometry of cutting tools

milling tool body

miller end

milling tool front terminal

For the cutting tools used for finishing, the cutting edge must have good profile accuracy.

Several possible profile deviations of cutting tools

Accurate contour;
The grinding process is not accurate enough, which results in irregular broken surface on the edge.
Radius deviation caused by inaccurate grinding process.

CUTTING TOOLS PROFILE DEVIATIONS

If the requirements for machining workpiece accuracy are very high, standard certified tools should be purchased from the tool manufacturer. KYLT CNC milling, CNC turning processes, adopt famous brand cutter to got high precision machined parts.

KYLT Aluminum CNC machining prototypes making service

On the premise of ensuring that the maximum overhang length of the tool shank and tool system does not exceed the specified value, in order to make the spindle operate accurately, the radial run out error of the tool must be detected at the tool shank and cutting edge respectively. If the radial run out error is too large, it will cause serious vibration of the spindle.

cutter radial run inspection

How to select suitable cutter

1) analyze the specific processing conditions, such as spindle and machine performance, tool clamping system, lubrication mode, etc.

2) analyze the material characteristics of the workpiece;

3) analyze the surface quality, machining accuracy requirements, cost, etc.

4) comprehensively consider various factors and make the optimal choice.

Calculation method of high speed cutting parameters

Three important formulas

Calculation method of high speed cutting parameters

Some important terms and processing parameters in high speed cutting

(1) cutting speed VC

Definition of cutting speed: VC = n * p * deff / 1000

VC refers to the appropriate cutting speed value suitable for high-speed machining of a workpiece material in the case of a specific tool. It refers to the linear speed of the tool.

cutting speed VC

How to set the value of cutting speed VC correctly:

Provided by tool supplier;
Refer to the existing experimental data;
Through a large number of cutting experiments to establish their own database.

VC value is an important basis for setting other cutting parameters correctly!

Effect of cutting speed on surface finish

EFFECT OF CUTTING SPEED ON SURFACE FINISH

Color comparison of iron chips produced at different cutting speeds

(2) effective tool diameter deff

Calculation of effective tool diameter and effective tool diameter.

EFFECTIVE TOOL DIAMETER

(3) feed rate of each edge FZ

Definition of feed per blade:

FEED RATE OF EACH EDGE

How to set the feed rate of each edge of the tool correctly:

Provided by cutting tool supplier;
Refer to the experimental data of other people’s research;
Through a large number of cutting experiments.

Whether the feed rate of each cutting edge is set correctly or not has a very important influence on the reasonable distribution of cutting load on the tool.

(4) axial and radial feed rate AP & AE

Calculation of axial feed:

Calculation of axial feed rate calculating example

The actual results will be affected by the spindle, tool and material.

The effect of AE and FZ on the finish

fz & ae cutting relationship

cutting finished surfaces

(5) calculation method of cutting parameters in high speed machining

CALCULATION METHOD OF CUTTING PARAMETERS IN HIGH SPEED MACHINING

(6) setting principle of CNC MACHINING parameters

In the process of high-speed machining, the machining parameters must be optimized and can not be set at will;
The value of cutting speed VC must be set correctly;
The feed rate of each edge FZ must be set correctly.

Reasonable value can not only bring the cutting efficiency of the tool to the limit, make full use of the tool, improve the machining quality and efficiency, but also will not affect the service life of the tool, so as to achieve the purpose of saving cost and achieving real high-speed machining.

KYLT Precision CNC machining services (milling & turning service), Fast prototyping, Fixture/Jig/Tooling making, Aluminum die casting & plastic injection parts. Email:cnkylt@aliyun.com +008615195010186

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roughing Machining & final machining

KYLT Precision CNC Machining — Sat, 14 Sep 2019 23:46:45 +0000

CNC machining works for Mold, Fixture, Prototype or other metal work pieces. Roughing machining and Final Machining are the necessarily processes.

What is Roughing Machining?

Roughing machining: Cut-out more materials from original blocks, bars by cutting tool.

Machine tool (CNC lathe, CNC milling machine, CNC router etc) adopts maximum load. Normally, the largest cutting tool should be selected, the largest feeding amount and fastest feeding speed be chosen. When use same cutting tool, the feed is inversely proportional to the cutter feeding amount.

Normally, the load of machine tools is not a problem. The principle of cutter selection is mainly based on whether the two-dimensional angle and three-dimensional arc of the product are too small. After choosing a good cutting tool, the length of the tool can be determined. The principle is that the length of the tool is larger than the machining depth. For large machining workpieces, the interference of the chuck should be considered.

CNC router rough machining

What is Final Machining?

Final Machining: The purpose of final machining is to meet the surface finish requirements and appropriate allowance reserved.

The final machining should be chosen large cutter and adopt fast cutting speed. Because the fine machining needs a long time, and a suitable feeding amount and feeding speed should be used.

Final machined Turning Part

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How to Avoid machined metal chip Entangling Workpieces

KYLT Precision CNC Machining — Wed, 04 Sep 2019 05:49:06 +0000

Working with metal part by turning or milling, the machined metal chip always entangling metal parts.

Normally, we can met following metal chip problems:

metal chip in machining process

1.Metal Chip winding, workpiece can not be loaded and unloaded

2.Metal Chips must be removed after the machining finished.

metal chip problem

3.Metal Chip winding and outlet blockage

4.Metal Chip winding, tools life short and damaged easily.

Do you have any chip trouble? If so, it means that you are not familiar with the workpiece machining. If this continues, someone else has processed 100 pieces, and you may only have processed 90!

What are the shapes of metal chips?

METAL CHIP TYPES

What can we read from cut metal chips?

metal chip shows machining problem

if the machined metal chip area broken, damaged. That means the cut tool was broken.
if the metal chip end has burr, it means the cutter tip damaged.
the metal chip color shows the cutting temperature in machining process.
if the metal chip has wavy cutting area, it means the cut tool was shacking in machining.

Cutting temp.（℃）	metal chip colors	Cutting Temp.（℃）	metal chip colors
200	Canary yellow	300	Cyan
229	Yellowish brown	320	Pale blue
240	brown	350	Blue-grey

Cut Metal Chip Principle and Direction

Principle	Method	Note
metal chip become thick	increase feeding	roughness become bad
metal chip become thick	cutter tip radius become small	roughness become bad damaged easily
metal chip become thick	Increasing Principal Deviation Angle	cutter tip strength become low
Metal Crimp Reduced radius	use suitable metal chip breaker	cutting resistance is higher, cutter shacking

What are the methods of Metal chip breaking?

Increasing chip thickness after feeding is beneficial to chip breaking

increase feeding in machining process

deep cut machining

2.The radius of cutter tip roundness decreases and chip thickness increases.

cutter tip radius

metal chip types

3.Reduce the front corner

Chip compression ratio = hc/h

The bigger the compression ratio is, the easier chip breaking will occur. At the same time, the cutting resistance will also increase.
Compression ratio is related to linear velocity Vc. When Vc decreases, compression ratio increases, so reducing linear velocity is also beneficial to chip breaking.
The decrease of the front angle, the large chip deformation and the increase of the compression ratio are beneficial to chip breaking.

Use sharp edge cutting tool

As photo show, under the same feed conditions, the blade has sharp edges, which is conducive to metal chip breaking.

sharp edge cutting tool

Increasing the main deflection angle and thicker chips are beneficial to chip breaking

main deflection angle increase

main deflection angle increase machined metal chip

Protruding chip breaking groove to promote chip breaking

Scraping the surface of the chip from the protuberance of the chip breaking groove produces a dent—-Significant increase in chip thickness—Promoting chip breaking is highly damaging

chip breaking groove

The contact area with chips decreases and the chips discharge smoothly due to smooth contact with protrusions—Less damage to cutting tools

cut tool use in machining

Reduction of Chip Curling Radius

choose suitable cutter in machining process

cutter typs usage in machining

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