In the mold manufacturing industry, in order to improve the accuracy of the product and the added value of the mold itself, the requirements for finishing surface finish are more and more strict, so it takes a lot of time and cost in subsequent processes such as manual grinding or polishing.
At present, the mold cavity finishing is aimed at eliminating manual grinding. For this reason, the company has introduced a "finishing milling" CBN single-blade end milling cutter for mirror machining with Rz below 1μm under high-efficiency machining conditions. . In order to reduce the cutting resistance, the bottom edge of the end mill is generally designed to have a positive wedge shape, so the state of the machined surface is determined by the arrangement of the path of the outer round bottom edge. In addition, there is also the problem that the cutting edges of the multi-blade end mills are affected by the beating of the cutting edges, and the cutting marks are not uniform, and the feeding cannot be improved. Generally, in the tool construction with large step and high efficiency machining, the number of cutting edges is increased, so that the cutting resistance is increased, and the deflection of the cutter body is increased, and it is difficult to achieve a surface finish of Rz 1 μm or less.
The "finishing milling king" CBN single-blade end milling cutter has a single-edged, convex-arc shape with a single-blade cutting edge and a slightly curved cutting edge from the outer diameter of the tool. Therefore, even if the tool is wobbled, the machined surface will be in the form of a large arc superposition, and it is possible to finish the surface finish with a surface finish of 1 μm or less, making it possible to replace the machining with the machining in the field of grinding. In addition, since the single-blade milling cutter is not affected by the jump and the wobble, the machining step can be increased to up to 70% of the tool diameter, and the surface finish can be less than 1 μm, which is higher than the multi-edge end mill. Mirror processing for efficiency. Taking into account the high hardness of the mold material, the tool uses CBN material to further improve the accuracy and life.
For example, the "finishing milling king" CBN single-blade end mill 12.5 (FON-1125) processing pre-hardened steel NAK80 (40HRC) is used as an example, using a vertical machining center for external spray cooling. When changing the step distance, the machining step can reach 70% of the tool diameter, ie 8.4mm; or when the feed rate is changed, even if the feed per revolution reaches f=0.2mm/rev, the finished surface finish can be maintained. Below 1μm, and the "finishing mill" has a life of more than 11 times that of coated end mills.
In the future, the high precision and long life of the cutting process will be more important. As the tool material and shape characteristics improve, the quality of the mold manufacturing will be further improved, and the cost will be further reduced.
Under high-efficiency processing conditions, mirror processing with Rz below 1μm can be achieved, and the lifetime is 11 times longer than that of coated end mills.
At present, the mold cavity finishing is aimed at eliminating manual grinding. For this reason, the company has introduced a "finishing milling" CBN single-blade end milling cutter for mirror machining with Rz below 1μm under high-efficiency machining conditions. . In order to reduce the cutting resistance, the bottom edge of the end mill is generally designed to have a positive wedge shape, so the state of the machined surface is determined by the arrangement of the path of the outer round bottom edge. In addition, there is also the problem that the cutting edges of the multi-blade end mills are affected by the beating of the cutting edges, and the cutting marks are not uniform, and the feeding cannot be improved. Generally, in the tool construction with large step and high efficiency machining, the number of cutting edges is increased, so that the cutting resistance is increased, and the deflection of the cutter body is increased, and it is difficult to achieve a surface finish of Rz 1 μm or less.
The "finishing milling king" CBN single-blade end milling cutter has a single-edged, convex-arc shape with a single-blade cutting edge and a slightly curved cutting edge from the outer diameter of the tool. Therefore, even if the tool is wobbled, the machined surface will be in the form of a large arc superposition, and it is possible to finish the surface finish with a surface finish of 1 μm or less, making it possible to replace the machining with the machining in the field of grinding. In addition, since the single-blade milling cutter is not affected by the jump and the wobble, the machining step can be increased to up to 70% of the tool diameter, and the surface finish can be less than 1 μm, which is higher than the multi-edge end mill. Mirror processing for efficiency. Taking into account the high hardness of the mold material, the tool uses CBN material to further improve the accuracy and life.
For example, the "finishing milling king" CBN single-blade end mill 12.5 (FON-1125) processing pre-hardened steel NAK80 (40HRC) is used as an example, using a vertical machining center for external spray cooling. When changing the step distance, the machining step can reach 70% of the tool diameter, ie 8.4mm; or when the feed rate is changed, even if the feed per revolution reaches f=0.2mm/rev, the finished surface finish can be maintained. Below 1μm, and the "finishing mill" has a life of more than 11 times that of coated end mills.
In the future, the high precision and long life of the cutting process will be more important. As the tool material and shape characteristics improve, the quality of the mold manufacturing will be further improved, and the cost will be further reduced.
Under high-efficiency processing conditions, mirror processing with Rz below 1μm can be achieved, and the lifetime is 11 times longer than that of coated end mills.
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