Innovative coating and improved structure to improve the processing quality and efficiency of end mills

In addition to some simpler planes, inner and outer circumferential surfaces, there are many difficult-to-machine curved surfaces, complex forming surfaces, elevations, etc.

The so-called efficient processing is to try to increase the cutting parameters, increasing the metal removal rate per unit time margin, shorten the processing time to improve the economic benefits of the coating line coatingol.

This article mainly introduces Mitsubishi's research and development achievements in this area, related improvements and specific measures

Although hard CBN end mills can be used for the milling of medium and high-hard steels, it is more economical to realize efficient processing by coating advanced and high-quality coatings on good cemented carbide base materials

MS + coated end mills coated right angle flat head, a rounded head at right angles, ball, long edge, short edge, long-necked like

Figure 2 The left 5 long-necked right-angled Ф2 end mill with a circular arc head, and an example of processing deep and long side walls and bottom surfaces is shown in Figure 3

The right 1, 2, 3, and 5 of Figure 2 are MS+ coated ball end mills.

The structural characteristics of the long tapered ball nose end mill in Fig.

Mitsubishi VF type end mills, single-phase nano (Al, Ti, Si) N coated end mills developed with IMPACT MIRACLE technology can process higher hardness parts and molds, and have been used in a variety of tools in hard materials A lot of achievements have been made in processing.

Figure 6 shows the VFR-coated short shank and ultra-short shank ball end mills used for general processing (Figure 6 top) and end mills used for finishing finishing (Figure 6 bottom)

One example is: using this coated short shank ball nose end mill with a radius of 3mm on a vertical machining center, the tool overhang is 22mm, and compressed air is blown to process HRC62 ASP23 powder high-speed tool steel.

The VFR-coated 2-flute short type (code S) ball end (code B) end mill model (bottom of Figure 6) that can be smoothed and processed.
It can process complex surfaces and surfaces at various angles on a five-axis machine tool.
It is very smooth and no knife marks are visible, and the measured roughness is below Rz=0.
8μm
.
The machined surface quality is high, the cutting conditions are the end mill ball nose radius 3mm, the tool speed n=20,000 rpm, the feed per minute F=600mm, the cutting depth along the surface 0.
015, lubricate with the minimum oil quantity of MQL, after cutting The residual amount of knife marks is invisible, and the efficiency is greatly improved than before (Figure 8)
.

 The same tool is used to process the curved surface cavity of STAVAX mold stainless steel on a vertical machining center at n=32,000rpm, V=603m/min, F=1,289mm/min, ap=ae=0.
02mm, tool overhang 15mm, blow Air-cooled cutting conditions, the surface quality of the machining result is smooth, and the vision is also very good, and the tool marks can not be seen when magnified 50 times
.
This type of stainless steel is approximately equivalent to 1Cr13 and 1Cr17 in our country.
It is generally difficult to process and has poor finish
.
It is not easy to achieve such a processing result .