What are the differences between different materials of metal high-speed cutting process?

From the design drawings of the parts to the parts of the finished product qualified delivery, taking into account factors such as the arrangement of the parts process route, the choice of machine tools, cutting tool selection, parts positioning and clamping and a series of factors, so as to avoid the quality problems that may arise due to the process of the program is not well thought out. From the perspective of high-speed technology to analyze the process characteristics of light metals, steel, cast iron, hard-to-cut materials, so as to be able to formulate the actual cutting process procedures, cutting dosage and tool parameters. The following is a brief introduction to the metal cutting process of different materials what are the differences:

A, what is high-speed cutting technology

High-speed cutting technology refers to the use of super-hard material cutting tools and abrasives, the use of high-speed movement can be reliably realized in high-precision, highly automated and highly flexible manufacturing equipment, in order to improve the cutting speed to achieve progress in the rate of removal of the material, the accuracy and quality of the advanced technology. With the use of CNC centers and flexible manufacturing systems in machine manufacturing, the mechanical assistance working hours have been greatly reduced. High-speed cutting of different workpiece materials, the cutting tools used, process methods and cutting parameters are very different, to grasp the characteristics of high-speed cutting process is an important part of high-speed cutting.

Two, the difference between different materials of metal cutting process

(1) high-speed cutting of light metals

Aluminum is the aircraft and various spacecraft parts of the main material, but also machines and instrumentation parts of the commonly used metal. Its relative density is very light, after appropriate treatment of aluminum alloy material. In recent years the use of aluminum alloys in automobiles and other power machinery is also gradually increasing. Aluminum-magnesium alloys are mostly used for castings, and the greatest advantage of these light alloys is their inherent ease of cutting.

(2) high-speed milling steel

High-speed milling is used for steel and cast iron finishing, especially the complex shape of the parts, high-speed cutting can greatly improve efficiency. High-speed milling of steel is the main topic of tool wear, optimization of cutting parameters is not only to improve the rate of metal removal, and more focused on reducing the cutting force, progress in the surface quality of the workpiece, dimensional accuracy and shape accuracy as well as reduce tool wear.

(3) High-speed milling of cast iron

In high-speed milling of cast iron, such as silicon nitride cutter for brittle tool materials, the main factors affecting tool wear is the shape of the insert and geometric parameters. In high speed milling of cast iron it is necessary to use round edged tools, otherwise the tool will be quickly damaged due to high brittleness, the choice of cutting speed depends on the tool material.

(4) High-speed cutting of difficult-to-cut materials

Difficult-to-cut materials include special alloy steels, titanium alloys, nickel alloys, etc., which are mostly used in aerospace manufacturing and power sections due to their high strength, hardness and impact resistance. However, these materials are easily hardened, have high cutting temperatures and severe tool wear. In the cutting of these materials, the typical form of blade failure is tool wear, especially in cutting high-strength alloys easily make the blade broken.

Three, cutting different metals how to choose the tool

(1) cutting light alloy tool selection

Because of the high speed cutting process in the light metal there is a large impact load, polycrystalline diamond and cubic boron nitride tool life characteristics are not good. Especially when cutting low melting point silicon aluminum alloy materials, to use diamond coated carbide tools; in milling aluminum magnesium alloy, the radius of the cutting edge fillet on the cutting temperature and the impact of the particulate spark are very large, carbide tool cutting edge radius must be precision sharpening to the nanometer level.

(2) high-speed milling steel tool selection

Tool wear during high-speed cutting is also affected by the strength of the material and other mechanical properties, the tensile strength of the workpiece material increases the tool life is reduced, so reduce the feed per tooth. In high-speed cutting tool materials, metal ceramic tool life than carbide long, coated carbide tool wear characteristics and the use of the tool matrix material has a great relationship.

(3) high-speed milling of cast iron tool selection

High-speed milling of cast iron parts material also affects the durability of the tool, the iron content of the cut material has a great impact on the durability of the tool. For carbide and cermet tools, the most important topic in high-speed cutting is tool wear. Metal-ceramic tools due to the advantages of high blade strength, low density and good chemical stability, its durability is better than cemented carbide, while silicon nitride tools are only suitable for cutting at relatively low feed speeds.

(4) difficult to cut material milling tool selection

In the high-speed cutting of titanium alloys, special alloys and heat-resistant nickel-based alloys and other materials in the experiments, smooth milling of the tool wear is significantly larger, the reason is that smooth milling of the tool in the workpiece away from the chip thickening, so that the chip sticking in the cutting edge to form the chip tumors. The high strength and elasticity of these materials, especially strain hardening increases the cutting load.

Four, the selection of special cutting oil

(1) light alloy workpiece cutting oil

Cutting copper, aluminum alloy, non-ferrous metals and other light metals, the cutting force and cutting temperature is not high, you can choose the proportion of anti-wear agent is not high, but has a good corrosion-resistant performance of the copper and aluminum alloy special cutting oil.

(2) cast iron workpiece cutting oil

Cast iron cutting need to choose a strong anti-rust cutting oil. Cast iron and bronze and other brittle materials, cutting often form a broken chip, easy to flow with the cutting oil everywhere, into the machine tool between the guide rail causing damage to the parts, you can use the cooling and cleaning performance of the cutting oil and do a good job of filtration.

(3) difficult to cut workpiece cutting oil

Cutting alloy steel, titanium alloy, if the amount of cutting is low, the surface roughness requirements are small, such as broaching and thread cutting requires excellent extreme pressure performance of the cutting oil, you can use sulfuric fatty acid esters as the main additives of extreme pressure cutting oil.