High-speed milling strategies in mould manufacturing

Abstract

High-speed cutting is one of the key issues in mould manufacturing. But to apply high-speed milling to mould manufacturing, unlike conventional milling, it is necessary to define specific cutting parameters. This article aims to define the influence of milling strategies and cutting parameters, such as cutting speed, feeding speed, cutting tool tilting angle, on the process stability.Long tool life and cutting strategy have a major influence on the results of machining hardened steel. Machining with drawing cut and down-cutting in copper and with drawing cut and up-cutting in hardened steel gave the best results with respect to tool wear and surface quality. Tool approach across the feeding direction results in heavy impact loads on the tool which lead to heavy tool wear and substantial dimensional deviations.Good surface quality is achieved in machining of a work piece of 2 363 steel (X100CrMoV51) hardened to 60 HRC, using the strategy of up-cutting with drawing cut and a tool approach with a tilting angle of 15 degrees. While up-cutting allows for achieving better surface quality, down-cutting provides longer tool life than up-cutting for all angles of approach.

Process Design Method of High Speed and Stable Cutting Hardened Steel

“…At present, the most of high speed cutting stability studies are aiming at the single factor analysis, given unilateral cutting stability control method of machine tool and tool, but can not solve the problem of cutting stability under the influence of many factors. In the actual machining process, tool, machine tool and workpiece as a whole to influence the cutting stability of hardened steel [10]. The vibration effects of each part of the process system should be stacked to the tool vibration.…”

Hierarchical Structure Model of High Speed Milling Hardened Steel

“…Automobile mould has the character of large size, complex structure, high requirements of dimension accuracy and processing surface precision, its surface processing requires great metal removal rate to reduce the total time, and it requires low cutting vibration and high surface quality [1][2]. By the impact of the change of surface curvature and hardness distribution, cutting loads and cutting process in high speed milling complex surface are in an unstable state, cutting vibration and processing surface quality decrease have a greater restraining effect to machining efficiency, has become the key problems to be solved in high speed precision milling hardened steel [3,4].…”