Product Development Technologies (PDT) (Lincoln, Illinois, USA) is a multinational company engaged in new product development including tool design and manufacturing. The company has been dedicated to the exploration and research of advanced processing strategies that can shorten the processing cycle and reduce production costs. Since its founding, PDT has carried out innovative technological research on tooling with high-feeding conditions using surface-coated TiAlN coated milling cutters (using APKT square stepped inserts). Since August 2004, a high-feed milling cutter with the brand name Twincut Vario (using the new LC280TT insert) was developed in cooperation with LMT-Fette USA (Cleveland, Ohio, USA). It is applied to the process test research of high efficiency mould processing.
In the final process test study, using the new Vario milling cutters that were manufactured and modified several times and the patented scraping technology summarized in this paper, the exhaust nozzle core box mold base of a certain type of automobile was processed. . The base has dimensions of 914 x 711 x 127 mm and the workpiece material is 4140 steel (30HRC). Machining was performed on a Makino MCB 1210 horizontal machining center with a power of 25 hp and a No. 50 spindle. The knife has a 178mm overhang in the processing. The results of the machining test were exciting. While ensuring the high precision requirements of the machined parts, a significant economic effect was achieved. The machining cost of the machine tool was reduced from US$12 per cubic inch to US$6, and the tooling cost decreased from US$31 per cubic inch to 2 In US dollars, the total production cost dropped from US$ 42 to US$ 8 per cubic inch, and the part’s production cost saved 81.6% over the original process. Sarullo, a manufacturing engineer at PDT, said, "We have reduced the processing time from 17 hours to 5 hours in the process test for efficient machining of molds."
PDT is also processing a different mold base using a Vario milling cutter with a diameter of 69mm, machining at a cutting speed of 139.3m/min, a spindle speed of 640rpm, a feed rate of 3m/min, and a depth of cut of 3mm. . In the past, the company used a conventional cutter with a diameter of 50.8mm, but it can only be processed with a cutting speed of 122m/min, a spindle speed of 764rpm, a feed speed of 0.78m/min, and a depth of cut of 5.08mm. Contrastive experimental studies have shown that the patented cutting chip technology and the unique 23o positive rake geometry of the Vario milling cutter can reduce the cutting forces acting on the cutting head by 50%, reducing tool wear and cutting temperature.
The main feature of the high-efficiency cutting chip processing technology is that it truly achieves high feed speed cutting. "This is the perfect application of the Vario tool. It is the best quality leap for PDT since its establishment." Sarullo said. Therefore, it can reduce the processing time from the past 17 hours to 5 hours when processing the mold cavity.
Vario milling cutter structure features
The Twincut Vario high-feed milling cutter uses a unique tool geometry (patented). The cutters are designed with two cutting edges that are misaligned (misaligned) in both axial and radial directions to allow for composite machining of parts. According to the processing conditions and the dimensional accuracy requirements of the parts, the two cutting edges of the tool with the upper and lower (axial) and left-right (radial) misalignment can perform high-efficiency cutting according to different cutting angles and adjusted cutting depths. The width-to-height ratio is only 1/4 of the previous chip cross section, which greatly reduces the cutting forces generated during machining, thereby giving full play to the cutting performance advantages of the tool.
Of course, this is also related to the unique design of the body structure. In the designed blade positioning groove, TC280TT inserts with different materials and 8 cutting edges can be installed with cutting edges with different positive or negative rake angles to further improve the cutting performance of Vario milling cutters. "The blade will not crack or crack," Sarullo said. "Even if the tool is heavily impacted in interrupted cutting, the cutting edge will not break. LC280TT blade shows a rare high in cutting." Durability makes the cutting edge always sharp, and carries out free cutting virtually without interruption (this is the cutting method that the cutting industry has been striving for), that is, to perform the powerful function of the metal '劈' (describe its speed) Processing of shredded chips (named after 'bashing' technology) rather than the usual way of extruding and cutting metals (relatively slow), due to its unique ultra-high cutting performance, only Will produce a very small volume of chips (about the past one-third)." Sarullo said, "In general, you only need to use air blow, you can remove small-size chips, clean the workplace, provide a Safe production environment."
In the past, when PDT was processing the same parts, the operator needed to carefully monitor the operating state of the spindle. The use of Vario cutters now frees the operator from stressful working conditions by avoiding the severe wear and tear that the tool can easily cause under harsh working conditions. He can safely do other tasks within the expected tool wear time. .
LMT-Fette's Vario cutter also solves the problem of previous cutters that generate large noise and vibration during cutting. “The next door to our production workshop is the CMM studio. Reducing interference is extremely important to the CMM studio,†says Sarullo. The Vario milling cutter with chipping technology can effectively reduce vibration under harsh processing conditions and maintain a quiet working environment.
Another advantage of the Vario cutter is that after the tool is adjusted, the part can be machined without the need to assemble the machining program, thereby reducing the additional time required for programming. “Under normal machining conditions, the machining status of the cutting steel is unpredictable, but when we use the Vario cutter, we can use the same machining program to machine the parts whose cutting conditions are not completely consistent and ensure good machining. Quality.†Sarullo went on to say, “In fact, we don’t have to think about the difference in processing conditions caused by the length of the material or the length of the tool.â€
Twincut Vario cutters and swarf cutting technology provide users with extremely high productivity, greatly reducing processing time, reducing tool and machine tool wear, extending tool life, reducing tooling costs, reducing vibration and noise, and improving safety in production environments. It provides good conditions for unmanned production, so it is a highly efficient processing technology with great development prospects.
In the final process test study, using the new Vario milling cutters that were manufactured and modified several times and the patented scraping technology summarized in this paper, the exhaust nozzle core box mold base of a certain type of automobile was processed. . The base has dimensions of 914 x 711 x 127 mm and the workpiece material is 4140 steel (30HRC). Machining was performed on a Makino MCB 1210 horizontal machining center with a power of 25 hp and a No. 50 spindle. The knife has a 178mm overhang in the processing. The results of the machining test were exciting. While ensuring the high precision requirements of the machined parts, a significant economic effect was achieved. The machining cost of the machine tool was reduced from US$12 per cubic inch to US$6, and the tooling cost decreased from US$31 per cubic inch to 2 In US dollars, the total production cost dropped from US$ 42 to US$ 8 per cubic inch, and the part’s production cost saved 81.6% over the original process. Sarullo, a manufacturing engineer at PDT, said, "We have reduced the processing time from 17 hours to 5 hours in the process test for efficient machining of molds."
LMT-Fette's Twincut Vario roughing an exhaust manifold mold.
PDT is also processing a different mold base using a Vario milling cutter with a diameter of 69mm, machining at a cutting speed of 139.3m/min, a spindle speed of 640rpm, a feed rate of 3m/min, and a depth of cut of 3mm. . In the past, the company used a conventional cutter with a diameter of 50.8mm, but it can only be processed with a cutting speed of 122m/min, a spindle speed of 764rpm, a feed speed of 0.78m/min, and a depth of cut of 5.08mm. Contrastive experimental studies have shown that the patented cutting chip technology and the unique 23o positive rake geometry of the Vario milling cutter can reduce the cutting forces acting on the cutting head by 50%, reducing tool wear and cutting temperature.
The main feature of the high-efficiency cutting chip processing technology is that it truly achieves high feed speed cutting. "This is the perfect application of the Vario tool. It is the best quality leap for PDT since its establishment." Sarullo said. Therefore, it can reduce the processing time from the past 17 hours to 5 hours when processing the mold cavity.
Vario milling cutter structure features
The Twincut Vario high-feed milling cutter uses a unique tool geometry (patented). The cutters are designed with two cutting edges that are misaligned (misaligned) in both axial and radial directions to allow for composite machining of parts. According to the processing conditions and the dimensional accuracy requirements of the parts, the two cutting edges of the tool with the upper and lower (axial) and left-right (radial) misalignment can perform high-efficiency cutting according to different cutting angles and adjusted cutting depths. The width-to-height ratio is only 1/4 of the previous chip cross section, which greatly reduces the cutting forces generated during machining, thereby giving full play to the cutting performance advantages of the tool.
Of course, this is also related to the unique design of the body structure. In the designed blade positioning groove, TC280TT inserts with different materials and 8 cutting edges can be installed with cutting edges with different positive or negative rake angles to further improve the cutting performance of Vario milling cutters. "The blade will not crack or crack," Sarullo said. "Even if the tool is heavily impacted in interrupted cutting, the cutting edge will not break. LC280TT blade shows a rare high in cutting." Durability makes the cutting edge always sharp, and carries out free cutting virtually without interruption (this is the cutting method that the cutting industry has been striving for), that is, to perform the powerful function of the metal '劈' (describe its speed) Processing of shredded chips (named after 'bashing' technology) rather than the usual way of extruding and cutting metals (relatively slow), due to its unique ultra-high cutting performance, only Will produce a very small volume of chips (about the past one-third)." Sarullo said, "In general, you only need to use air blow, you can remove small-size chips, clean the workplace, provide a Safe production environment."
In the past, when PDT was processing the same parts, the operator needed to carefully monitor the operating state of the spindle. The use of Vario cutters now frees the operator from stressful working conditions by avoiding the severe wear and tear that the tool can easily cause under harsh working conditions. He can safely do other tasks within the expected tool wear time. .
LMT-Fette's Vario cutter also solves the problem of previous cutters that generate large noise and vibration during cutting. “The next door to our production workshop is the CMM studio. Reducing interference is extremely important to the CMM studio,†says Sarullo. The Vario milling cutter with chipping technology can effectively reduce vibration under harsh processing conditions and maintain a quiet working environment.
Another advantage of the Vario cutter is that after the tool is adjusted, the part can be machined without the need to assemble the machining program, thereby reducing the additional time required for programming. “Under normal machining conditions, the machining status of the cutting steel is unpredictable, but when we use the Vario cutter, we can use the same machining program to machine the parts whose cutting conditions are not completely consistent and ensure good machining. Quality.†Sarullo went on to say, “In fact, we don’t have to think about the difference in processing conditions caused by the length of the material or the length of the tool.â€
Twincut Vario cutters and swarf cutting technology provide users with extremely high productivity, greatly reducing processing time, reducing tool and machine tool wear, extending tool life, reducing tooling costs, reducing vibration and noise, and improving safety in production environments. It provides good conditions for unmanned production, so it is a highly efficient processing technology with great development prospects.
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