Application of coating in shaft processing

The changing processing tasks constantly put new demands on single or small batch part manufacturers. If you want to gain the advantage in the fierce competition, you must use high-efficiency milling tools. The first task is to meet the requirements of process and economy.
The competition between most tool and mold manufacturers is reflected in the services they can provide: for example, the size, materials, processing, and precision of the parts that can be machined. Personalized strategies can improve on time and cost pressures, and can advise on process optimization to service.
One of the difficulties is the production efficiency, which is also a major challenge faced by most processing companies. In order to optimise costing and increase competitiveness, tool manufacturer Paul Horn has developed a series of products for different applications and materials, including DS series full carbide cutters, DA series end mills and spiral end mills. DM series combined cutter.
In general, the user selects the tool according to the product manual or according to special specifications. Therefore, the rich and varied tool and die manufacturing industries require high flexibility and short lead times. In addition, Horn has been engaged in tool development for many years and has analyzed numerous application cases. This has given them a strong professional ability and is also conducive to solving complex milling problems.
A medical device manufacturer hopes to simplify the casting process of cylindrical supports by providing a funnel-shaped gate. WF Fottner, from Moessingen near Tuebinen, took the task and used four stencils to make the required two-piece injection mold.
The goal is to carry out 2 million machinings. The mold has an edge length of 500 mm and a special contour has been designed according to the user's requirements. The purpose is to achieve 2 million machining operations. The company has designed a special tool for this purpose and is a tool. Found a special process. This cooperation with the tool makers in Tuebingen not only shortens the geographical distance, but more importantly satisfies the requirements for the types of tools, efficiency, precision and economy.
The first task is to rough process the closed edge of the template. The material is hot work die steel 1.2343 ESU. The specific machining parameters are as follows: Use the DM series of angle milling cutters, the diameter is 12 mm, the radius of the cutting head is 2 mm, And use a 0.2 mm gauge block for inspection control. The process is characterized by the use of patented parts for connecting the shank and the blade, which can be used in diameters ranging from 8 to 12 mm.
Since the holder acts as a holder for the various diameters of the insert, the fit between the inserts needs to be very precise, so that it is necessary to select tools as few as possible in accordance with the cutting parameters for more economical machining.
The carbide shank has a wide range of lengths and has a collapsible structure. The use of a holder with a length of up to 140 mm allows access to the inside of the cavity and enables very high radial accuracy.
Due to the reasons for the delivery period and to make better use of the machining center's capabilities, two brass electrodes can be mounted next to the machining center template for machining additional spray-casting molds. Although the milling parameters of the two are different (different from the template, the brass electrode needs a wet environment), but because you can use the DM series milling cutter alone, it also makes the NC programming process relatively simple.
The brass cutter on the product catalog can have 2, 3, and 4 cutting edges, respectively, and the cutting circle has a diameter range of 0.3 to 12 mm. The recommended machining parameters for the rough machining with the electrode are: using 2 to 4 blade round and full radius structures, semi-finishing and finishing of the wire die can use a double-edged micro-milling cutter with a diameter of 0.3-2 mm.
The DS series of multilateral solid carbide milling cutters DS series cutters can be used for the finishing of stencils with hardness exceeding HRC55. This series of milling cutters with different structures can have up to 16 cutting edges and can be used to machine brass, graphite, aluminum, plastic, soft and hardened steel and titanium alloy parts. Different hard metal and coating treatments allow the “soft-hard milling” process to reach a HRC60 range, while the hard milling range can reach HRC56-70. The quality grade of the tool holder reaches H5 grade, and it can get 0.005 grade radial accuracy, which is very suitable for the final finishing.
This accuracy mainly comes from the 4 guide rails and the cavity used to support the template. In addition, special surface structures can also be obtained by etching processes after finishing. The DSMR six-blade end mill has a diameter of 6 mm and a corner radius of 1 mm, enabling finish machining without leaving any cutting marks.
Helical end mills increase production efficiency The versatility and economy of the DS system can be demonstrated with four templates of 1.2343 ESU and a DSK double-blade full radius cutter with a ball head diameter of 8 mm.
The third component of the milling system is the DA series of end mills and spiral head mills, which can be used to finish side-spraying templates of 1.2312 material. The 16-, 20-, 25-, and 32-mm size DA Series feature a reversible 3-blade construction. This structure ensures high cutting stability and can provide an axially polished geometry for parts with higher surface quality requirements.
According to the radial and axial machining processes, different cutting rake angles are set. According to different processing technology matching templates, 90 degree shaft shoulders can be obtained with two blades, and the precision is extremely high.
For deep milling, a contact width of 3 mm or 4.5 mm can be selected depending on the size of the plate. In addition, a sinking depth of 1 mm can be achieved. All brackets and holders in the DA series are hard-coated.
Milling cutter series brings many benefits The DS, DA and DM milling cutter systems have proven their usefulness in relatively simple double-pole machining applications. DSMR series cutters are also widely used because of their long service life.
In the DM system, patented connectors are used between the holder and the milling cutter. Different combinations of inserts and holders can be used. With a 0.01 mm tool change accuracy, machining accuracy can also be improved.
The high quality housing and the three-blade rotary structure possessed by the DA system can improve the processing economy of the spray casting mold.
Finally, the tool supply process has also been simplified. Uniform naming, dimensions, parameters, and processing recommendations simplify the monitoring and programming of the entire process.