Diamond cutters include the most frequent sorts of cutting tools, basically with the matrix and diamond tool consisting of two parts, really easy, many manufacturers will work regarding how to improve the Diamond cutter. Compressor of the very lots of applications, a compressor is normally consisting of hundreds or 1000s of components, complex manufacturing process, technical requirements. So that you can match the production needs of the numerous parts, tooling and fixture is very important to reasonably designed with, in order to meet certain requirements of good, fast, and has to be improved and also on several diamond cutting tools and tooling design. Give three examples below:
Improvement, straight shank end milling cutter
2Cr13 chromium steel material in the packed Chamber, face width 12mm, dark 20mm, 200mm diameter ring groove. Initially using §? made 12 straight shank end mills for broadband steel processing, deep 5mm, processing and adhesion of diamond chip is below 5 minutes within the milling cutters, deteriorating cutting, milling cutter edge collapse, tool change frequently in the process, efficiency is incredibly low, machining a diamond ring groove to 150 minutes. Use after Japan's Mitsubishi diamond carbide milling cutter, although the performance is superior to for the former, but chip chip-stacking capacity there is tank problem, when automatic processing at the processing center, edge collapse, and even the tool appears broken.
Saw blades production utilizing the same cutter. Saw blade manufacturing process may be relatively backward, improved results over the years is tiny, no breakthroughs recently, after higher than a year of research and development because of the Eastern industrial automation limited, production of CNC gear drive devices, production pictures progress on saw blade technology, its device term for the saw blade automatic open CNC gear hobbing machine (CNC gear opened presses). Figure
Saw open effect of tooth-CNC turret punch press, high precision, small cuts better, equipment investment, high production efficiency, replace the automated mechanical punching machine, well suited for large batch line use. High penetration of automation, saving labor and improve yield.
Second, improvement of milling flange diamond tools
Spiral tooth clutch one-way shape to spiral end face structure, torsional moment of which passed itself off only when it's above a certain value, also referred to as safety clutch. Around the miller processing of the most extremely widely used technique is a technique for dividing head gear, calculated based on the lead change, configure the appropriate implementation of change between head and table piece uniform rotation and uniform motion, thus processing the Archimedes curved surfaces. Tool selection ф 8~ ф 10 State milling knife, on knife Shi necessary to Diamond milling knife cutting edged and workpiece axis phase cut, operation Shi tool fell to requirements depth Hou, min of handles insert min of Board hole within, shake min of handles 20 ring, in min of head rotating of while, table for longitudinal into to, makes workpiece for composite movement, are spiral slot; elevation tool, reverse turns min of head handles 20 ring, pull bolt, continues to shake min of handles 20 ring, insert bolt, and repeat above steps processing another a spiral slot.
These costly processing methods, and cannot be processed prior to drawings, stop at your tooth root Cutter radius. Need manual repair file root part keeps its R0.5, low efficiency, accuracy is just not guaranteed.
This phenomenon, mcdougal after careful analysis, and using CAD-aided design, thought we would complete the initial tooling and tooling improvements. Theoretical calculation of diamond cutlery angles, shape, over, also has begun to consider shape, required is the place to processing tool.
On reflection, I personally use existing universal tool and Cutter Grinder for machining of workplace, ф 22 domestic broadband steel in spiral taper shank endmill with restructuring, front first grinding milling cutter, tyrannize tapered, single slope of 8 °. So grinding angle, enhances the chip capacity slot space, avoid more quick milling passes diamond chip stacking behavior occurs. As soon as the last operation was sharpening angle, angle is just too big small you can't start cutting pieces, therefore it is simple increase the risk for tool cutting edge break. Processing just for this tool, point after selecting 8 ° after ' quality 45# steel, try straight cutting effect is right, very smooth if the knife cuts deep 10MM.
Structure principle of three, tooling,
Its main part screw, right-handed helical teeth. Its working principle is always to turn hand wheel and drive the screw dextrorotation, helical gears for counter clockwise (based on the stress analysis of helical gear, levorotation, axial force f up), arrived a lead concurrently a week, simple structure and easy.
Tool after installation on milling machine spindle, vertical milling head turn clockwise to tug 7.5 °, level clamping tooling to milling machine working bench, where parts fit. After trying obtain the effect is shocking, the entire spiral flange process took only 5 minutes to accomplish, more cost-effective compared to original 5 times times, tool our life is the initial twice times, achieved once in most 200 grinding machining innovative, reuse tools approximately 10 times fully stick to the drawings and aspects of the standards. Ahead of that, spiral flange have try in three-axis machining vertical machining center with ball-end milling cutters (milling cutter machining helicoids interference), not really a longer processing time, and left the tool Nose Radius with the tooth root, governed by secondary processing.
2012年5月23日星期三
General knowledge of diamond cutter
Before user inside the selection and use of diamond coated cutting tools, you will need to understand the subsequent several points regarding the diamond-coated tools common sense:
(1) Difference between CVD diamond-coated with amorphous diamond coating?
Amorphous diamond (generally known as diamond-like carbon--photograph) coating can be a carbon film deposition using the PVD process. It has both section of SP3 diamond, and part of SP2 carbon; a higher film hardness, but under the hardness of diamond-like carbon film; its thickness is thinner than we usually deposited diamond film. When processing graphite, amorphous diamond coating cutlery life usually are not 2-3 x the coated cemented carbide tool. By contrast, CVD diamond can be a pure diamond coatings deposition while using the CVD process, is the tool lifetime of cemented carbide cutting tools in machining graphite 12-20, so that you can reduce tool change times, increase the reliability, consistency and accuracy of processing.
(2) No machining of hardened steel with diamond tool?
Diamonds are formed from carbon atoms. Some material when heated, will aspirate carbon atoms in diamond and form carbides inside workpiece. Iron is just one of such materials. Whenever using diamond tool machining of iron materials, friction heat generated will spread for the carbon atoms of iron in diamond, which caused early failure as a result of chemical wear of diamond coating.
(3) heavy grinding and (or) heavy coating of diamond film coated tools quality challenging maintain because of the tool surface coating for pure diamond, diamond grinding wheels for cutter Regrinding needs a number of years. Furthermore, make it possible for the development of diamond cutting tools. Chemical properties in the preparation process will change the tool surface, due to the coating requires very precise control on the chemical characteristics, effect of cutter coated again can hardly be guaranteed.
(4) the life span of diamond coated cutting tools vary?
As with every other tool, diamond coated cutting tool life expectancy varies, dependant upon cutting materials, number of cutting speed and feed rate, and also the geometry of the workpiece. In the main, graphite machining carbide tools coated with diamond coated cutting tool life's not 10-20, in some instances even longer. In this way, you can do nearly every task processing by having a tool, no tool wear and tool change, avoid processing interrupt and recalibrate, rendering it possible to offer the unattended processing. Inside the processing of composite materials, may also get yourself a longer tool life.
It can be reported that in processing high density fiberglass, when machining composite materials like graphite and Gl0-FR4, of diamond coated cutting tools which aren't coated cemented carbide tool life can be as high as 70 times.
(5) coated with diamond peeling on the coating can prevent peeling is really a significant issue of diamond coated cutting tools, or a faqs (particularly machining materials such as carbon fibre), will result in tool own life is hard to forecast. Late 90 'of the past century, surface chemistry characteristics were identified as is a factor influencing the performance of diamond-like carbon coating adhesion. By choosing the good compatibility of pretreatment of cemented carbide chemical characteristics, the employment of appropriate technology and sedimentary respond to reasonable conditions, it is possible to reduce or remove the diamond coating peeling, stability of steady wear pattern. Within microscope observation of normal depreciation of diamond coated cutting tools come in, diamond was worn before cemented carbide substrate by stability, without edge collapse or slack.
(1) Difference between CVD diamond-coated with amorphous diamond coating?
Amorphous diamond (generally known as diamond-like carbon--photograph) coating can be a carbon film deposition using the PVD process. It has both section of SP3 diamond, and part of SP2 carbon; a higher film hardness, but under the hardness of diamond-like carbon film; its thickness is thinner than we usually deposited diamond film. When processing graphite, amorphous diamond coating cutlery life usually are not 2-3 x the coated cemented carbide tool. By contrast, CVD diamond can be a pure diamond coatings deposition while using the CVD process, is the tool lifetime of cemented carbide cutting tools in machining graphite 12-20, so that you can reduce tool change times, increase the reliability, consistency and accuracy of processing.
(2) No machining of hardened steel with diamond tool?
Diamonds are formed from carbon atoms. Some material when heated, will aspirate carbon atoms in diamond and form carbides inside workpiece. Iron is just one of such materials. Whenever using diamond tool machining of iron materials, friction heat generated will spread for the carbon atoms of iron in diamond, which caused early failure as a result of chemical wear of diamond coating.
(3) heavy grinding and (or) heavy coating of diamond film coated tools quality challenging maintain because of the tool surface coating for pure diamond, diamond grinding wheels for cutter Regrinding needs a number of years. Furthermore, make it possible for the development of diamond cutting tools. Chemical properties in the preparation process will change the tool surface, due to the coating requires very precise control on the chemical characteristics, effect of cutter coated again can hardly be guaranteed.
(4) the life span of diamond coated cutting tools vary?
As with every other tool, diamond coated cutting tool life expectancy varies, dependant upon cutting materials, number of cutting speed and feed rate, and also the geometry of the workpiece. In the main, graphite machining carbide tools coated with diamond coated cutting tool life's not 10-20, in some instances even longer. In this way, you can do nearly every task processing by having a tool, no tool wear and tool change, avoid processing interrupt and recalibrate, rendering it possible to offer the unattended processing. Inside the processing of composite materials, may also get yourself a longer tool life.
It can be reported that in processing high density fiberglass, when machining composite materials like graphite and Gl0-FR4, of diamond coated cutting tools which aren't coated cemented carbide tool life can be as high as 70 times.
(5) coated with diamond peeling on the coating can prevent peeling is really a significant issue of diamond coated cutting tools, or a faqs (particularly machining materials such as carbon fibre), will result in tool own life is hard to forecast. Late 90 'of the past century, surface chemistry characteristics were identified as is a factor influencing the performance of diamond-like carbon coating adhesion. By choosing the good compatibility of pretreatment of cemented carbide chemical characteristics, the employment of appropriate technology and sedimentary respond to reasonable conditions, it is possible to reduce or remove the diamond coating peeling, stability of steady wear pattern. Within microscope observation of normal depreciation of diamond coated cutting tools come in, diamond was worn before cemented carbide substrate by stability, without edge collapse or slack.
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