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Tool and tool clamping is one of the key factors to ensure the success of titanium alloy machining


Release time:

2016-05-12

Tool and tool clamping is one of the key factors to ensure the success of titanium alloy machining

 

The machinability of titanium alloys is poor and the processing window is small. In addition to the tool itself, many other factors also affect the processing of titanium alloys. In order to ensure the success of titanium alloy processing, special attention needs to be paid to four aspects: coolant pressure and flow rate, programming skills, machine tool must have the condition, tool and clamping.

1. Coolant pressure and flow

The first problem is the coolant, which has a great influence when cutting titanium alloys. The advice available is simple: always use a large amount of coolant when cutting titanium alloys and apply high-pressure cooling (HPC) whenever possible.

Compared with conventional pressure cooling, the tool life can be doubled when using high-pressure cooling. High-pressure cooling makes it easier to eliminate chip bonding and prevents tool damage caused by re-cutting of chips.

2. Programming skills to ensure the best tool path

It takes more time to formulate a fully optimized machining program than to use a ready-made fixed cycle in a CAM system. If only one part is processed, the effect will outweigh the gain. However, if the processing of this part is to last for several years, it is worth doing the best from the beginning.

Optimized programming can increase production efficiency by up to 50%, while achieving longer tool life and higher process safety. The top programming priorities are stated below.

3. Requirements for machine tools

The machine tool itself, of course, has a huge impact on output. At different speeds, power and torque requirements, the machine must work properly in a variety of applications.

4. Tool and tool clamping

The fourth key factor is to use the right tool to find the balance between the main deviation angle, the number of teeth and the best metal removal rate. The following gives the tool selection optimized for common titanium alloy machining applications.

Face milling:

Due to the smaller actual main deflection angle and chip thinning effect, round blade tools can provide the best production efficiency and tool life. CoroMill 300 cutting is very brisk. The internal cooling design and the dense teeth option make this tool the best choice for face milling of titanium alloys. The CoroMill 300 is also well suited for helical interpolation milling and solid hole milling. The latest introduction of the diameter of 20mm (metric) or 1.0 inches (inch) specifications of the blade and the corresponding knife body.

2D profiling and cavity processing:

Long-edge end mills are high-performance tools with extremely high metal removal rates, specially developed for titanium alloy processing. The special axial positioning design at the bottom of the blade not only prevents the blade from moving, but also safely and reliably achieves a high metal removal rate. The cutting tool is light and the required power is very low. Each coolant hole orifice is threaded to facilitate installation and use of small diameter nozzles suitable for high pressure cooling applications.

Insertion milling:

Under stable conditions, feeding along the Z axis is not the preferred processing method. However, the working conditions are not always stable, and plunge milling is a good choice for weak workpiece clamping and large tool overhang. In order to maintain higher production efficiency, it is very important to be able to obtain a reasonable cutting depth. The maximum cutting depth of the CoroMill 215 is 22mm(0.85 inches).

Semi-finishing and finishing:

For semi-finishing and finishing in deep cavities (with a small corner radius and a large bottom transition radius), a long tool with a necked shank is required.

The CoroMill 316 is a newly launched product. Its unique interface is tapered, with an axial positioning surface and a radial positioning cylindrical surface at the tail. It can provide excellent radial and axial positioning accuracy and unique bending rigidity. This makes it a perfect tool for safe and reliable processing.