Analyzing Ten Points Using Grooving Tools
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2) Processing Machines and Applications In the grooving process, the design patterns and technical conditions of the machine tools are also essential elements to consider. Some of the main performance requirements for machine tools include: enough power to ensure that the tool runs in the correct speed range without stalling or jolting; high enough rigidity to complete the required cutting process without flutter; With a high enough coolant pressure and flow to help chip removal; with high enough accuracy. In addition, proper commissioning and calibration of the machine tool are also crucial in order to produce the correct groove shape and dimensions.
3) Understand the characteristics of the workpiece material Familiar with some characteristics of the workpiece material (such as tensile strength, work hardening characteristics and toughness) is very important to understand the impact of the workpiece on the knife. When machining different workpiece materials, different combinations of cutting speed, feed amount, and tool characteristics are required. Different workpiece materials may also require specific tool geometries to control chips, or use specific coatings to extend tool life.
4) Choosing the right tool Choosing and using the tool correctly will determine the cost-effectiveness of the process. The grooving tool can process the workpiece geometry in two ways: first, the entire groove shape can be machined through one cut; second, the final groove size can be roughed through multiple steps. After choosing the tool geometry, consider a tool coating that improves chip removal performance.
5) Forming tools should be considered for forming tools in high-volume machining. Forming tools can cut out all or most of the groove shape in a single cut, freeing the tool position and shortening the machining cycle time. One disadvantage of non-blade forming tools is that if one of the teeth is broken or worn faster than the others, the entire tool must be replaced. Another important factor that needs to be considered is controlling the cutting tool and the machine power required for forming cutting.
6) Selecting a single-point multi-tool A multi-tool tool can generate tool paths in the axial and radial directions. In this way, the tool can not only machine the groove, but also turn the diameter, interpolate the radius, and machine the angle. The cutter can also be multi-directionally turned. Once the insert enters the cut, it moves axially from one end of the workpiece to the other while maintaining contact with the workpiece at all times. The use of multi-tools allows more time for cutting workpieces than for tool change or idle travel. Multi-purpose tools also help reduce the entire workpiece machining process.
7) Proper planning of the optimum machining sequence in the correct machining sequence requires consideration of various factors, such as the change in workpiece strength before and after the machining of the grooves, because the strength of the workpiece will be reduced after the grooves are first machined. This may cause the operator to use less than optimal feed and cutting speed in the next process to reduce chatter, and reducing cutting parameters may result in longer machining times, shorter tool life, and unstable cutting performance. Another factor that needs to be considered is whether the next process will push the burr into the processed groove. As a rule of thumb, consider that after finishing the OD and ID turning, first start machining from the point farthest from the tool chuck and then machine the groove and other structural features.
8) Effect of feed amount and cutting speed Feed amount and cutting speed play a key role in groove processing. Incorrect feed rates and cutting speeds can cause chatter, reduce tool life, and increase cycle times. Factors that affect feed and cutting speed include workpiece material, tool geometry, type and concentration of coolant, blade coating, and machine tool performance. In order to correct the problems caused by the unreasonable feed rate and cutting speed, secondary processing is often required. Although various sources of information for "optimized" feeds and cutting speeds can be listed for a variety of different tools, the most up-to-date, most useful information is usually from tool manufacturers.
9) Selecting a blade coating can significantly increase the life of carbide inserts. Because the coating can provide a lubricating layer between the tool and the chip, it can also shorten the processing time and improve the surface finish of the workpiece. Currently used coatings include TiAlN, TiN, TiCN, and the like. For optimum performance, the coating must match the material being processed.
10) The correct application of the cutting fluid means the provision of sufficient cutting fluid for the cutting point where the grooving insert contacts the workpiece. The cutting fluid plays a dual role in cooling the cutting area and helps with chip removal. When machining blind bore inner diameter grooves, increasing the cutting fluid pressure at the cutting point is very effective for improving chip removal. For trench machining of difficult-to-machine materials such as high-toughness, high-viscosity materials, high-pressure cooling has clear advantages.
The concentration of water-soluble oil-based coolant is also critical for groove processing of difficult-to-machine materials. Although the typical coolant concentration range is 3%-5%, in order to increase the lubricity of the coolant and provide a protective layer for the tool tip, it is also possible to test the effect of increasing the coolant concentration (up to 30%).