The efficient treatment of whorl

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Thread machining of overview of Css" Type=text/css Rel=stylesheet>1 is one of terminal working procedure of pull current Cheng, the work that costly treatment course already passed before the quality problem in thread machining makes likely is destroyed at once. In competition intense market environment falls, requirement fact is mixed quickly, effectively now reliable thread machining. Efficient thread machining (High Performance Threading, HPT) is to point to efficient cutting is used when tap and whorl form cutting (HPC) technology, it needs to consider all and relevant essential factor, and it is cutting tool only not just. In tap and whorl form cutting, to exit cutting tool, machine tool main shaft needs to invert normally, the cutting speed that this makes can be used is restricted. In introduce efficient thread machining (when HPT) technology, because raise the action of cutting speed to suffer,be restricted, because this is other,element becomes more important. Besides cutting or figuration cutting tool, still need to consider collet of thread machining principle, cutting tool and cutting tool clip to hold, treatment craft, refrigeration is lubricant, and consider those who process the monitoring of the process and product to detect further, metric with measure calibration. Handling time, auxiliary time, installation time and detect time also must give consideration. Only will all these element are combined well, just realize efficient thread machining likely. The article will undertake commenting to afore-mentioned element, the introduction realizes efficient thread machining successfully and the solution of thread machining of tall profitability of final translate into. Efficient cutting already became 2 efficient thread machining a well-known concept. But, to all sorts of different cutting technology, the attention of efficient cutting also differs somewhat mainly. Among them, thread machining is a kind of very special treatment kind. The article tries to answer the following question: What is efficient thread machining? How to realize efficient thread machining? What profit does efficient thread machining have? Efficient thread machining is meant raise total cutting tool to machine efficiency (the whorl amount) that here basically points to to unit time is machined. To realize efficient thread machining, need to raise cutting rate of course. But tap and whorl form cutting need machine tool main shaft to invert normally in order to exit cutting tool, because place of machine tool ability is restricted, this increases scope with respect to what limitted cutting rate. Accordingly, a few otherer element (if handling time, auxiliary time, installation time is mixed,detect time) become more important. Efficient thread machining still means treatment quality, avoid to discard as useless or fall rate of do poorly done work over again to lowest, this included whorl to detect and measure calibration. Finally, still must pass course of the thread machining that monitor, be forecasted in time before all sorts of problems appear and be on guard, avoid the nonproductive time that appears to foreknow hard thereby. To realize efficient thread machining successfully, with respect to the whole process that must consider thread machining in the round. 3 whorl profile and thread machining method have the whorl profile that makes a variety of differring, the whorl outside including and inside whorl. Thread machining method is very much also, the article basically discusses 3 kinds the most important inside thread machining technology: Form cutting of tap, whorl and whorl milling. These craft characteristics that machine a method see a table 1. The craft characteristic tap that expresses method of 1 thread machining machines milling of whorl of whorl form cutting to machine ① to have bits cutting treatment; ② successive cutting; ③ main shaft inverts; The whorl inside ④ treatment; ⑤ carries cutting sword statified material of purify of process of broaching of cutting → helix; Material of ⑥ cutting tool basically is high-powered high-speed steel (HSS-E) , also use hard metal sometimes; ⑦ is used not coating and coating cutting tool; ⑧ suits to process data: HRC55 of ≤ of HSS-E cutting tool; HRC63 of ≤ of hard alloy cutting tool. ① little bit is machined; ② divides a pace (statified) form cutting; ③ main shaft inverts; The whorl inside ④ treatment; ⑤ forms whorl through material move; Material of ⑥ cutting tool basically is high-powered high-speed steel (HSS-E) also uses hard metal sometimes; ⑦ is used not coating and coating cutting tool; ⑧ suits to process data: ≤ 1200N/m2; ≥ of burst meet an emergency 8% . ① has bits cutting treatment; ② interrupted cutting; ③ main shaft does not invert; Inside ④ treatment, outside whorl; ⑤ passes data of three-dimensional and drossy purify; Material of ⑥ cutting tool basically is hard alloy, also use HSS-E sometimes; ⑦ uses coating cutting tool normally; ⑧ suits to process data: HRC60 of ≤ of hard alloy cutting tool. 4 whorl milling this is method of a kind of cutting having bit that uses interrupted cutting means. Workpiece material is excised with means of interpolation of a kind of three-dimensional helix (form short comma shape to cut bits) , whorl is mixed inside outside whorl all can be machined. When milling whorl, main shaft and cutting tool need not invert. Watch 2 use cutting tool for method of milling of a few kinds of whorl and place. One of advantages of whorl milling are to use a cutting tool to be able to machine a tooth of a few kinds of whorl model. Express method of 2 whorl milling and its cutting tool whorl of milling of basic technology whorl gets mill beforehand aperture type is gotten beforehand Kong Mo beforehand milling of whorl of type of razor blade of milling of whorl of aperture craft convention gets mill taper of GFGF(of type of the circumferential treatment that get mill) GSFEPWSPBGFZBGF gets mill to machine is efficient treatment whorl. Use this kind of method, can complete drill with a cutting tool only, pour horn and whorl milling treatment, can shorten thereby blame treatment is auxiliary time and the time that change a knife. Get milling cutter to be able to be used at processing aluminous, casting aluminium and cast-iron work. Must point out, use whorl milling technology, still can realize treatment of horniness whorl milling. For example, with a H model circumferential get milling cutter (the treatment on the hard data that ZBGF H) can be HRC58 in hardness gives whorl (go up to the workpiece after heat treatment omission whorl is a kind very perfect remedy methodological) . Of course, whorl milling also has the problem that a few need solve, be like process designing of tooth compensation, treatment, and a few issues that treatment loop inside and outside needs to consider technically. An advantage of whorl milling is OK purify is in screw only then dot and the not complete whorl that terminus is in. To improve productivity further, whorl getting milling cutter is OK still with a kind in order to nod (or upright ministry) affirmatory and phasic cutting tool combination is used. This kind modular system (Mosys) cutting tool can operate treatment to give complex opening through / whorl / structure of combination pouring wine cup. 5 tap tap is the thread machining means of a kind of successive cutting, cutting having bit. The cutting tine that workpiece material increases by degrees through radial dimension is excised by one after another, this means tap is means of treatment of broaching of a kind of helix. Tap uses fusion high-speed steel or pulverous metallurgy high-speed steel normally (HSS-E) is made. Below certain circumstance, tap material also can use hard metal. Tap can be used at machining hardness to be in the workpiece material under HRC63. Of tap helix chamfer come back to have very big effect to cutting tool, be decided by machines via whorl or grain of blind Kong Luo then, left chamfer coming back is used when machining via, dextral chamfer is used when machining blind aperture (machine dextral whorl) . Normally, every kinds of chamfer metropolis forms a few kinds to cut bits to coil. Cut bits consistent or the direction of going from place to place in the chamfer that discharge bits and way of cutting tool feed are opposite. Cutting force and the direction of the chamfer that discharge bits will cause different counterforce, pull cutting tool Kong Zhong or prevent cutting tool to advance. Tap collet should give to these force compensation. Tap regards a kind of complete treatment as the process, need considers the following parameter and its interaction: Craft of appearance of geometry of workpiece material, cutting tool material, cutting tool, treatment, knife handle and machine tool, coating and refrigeration / lubricant. If revise among them a parameter, with respect to the implicative change that can cause other parameter, because this needs,also undertake be adjustmented accordingly to these parameter. Especially to tap, adjust treatment parameter impertinently to may reduce thread machining function and / or shorten cutting tool life. Tap and other treatment kind are different, it has only (it is only inside certain limits) optional cutting parameter (namely cutting speed Vc)(sees watch 3) . Accordingly, all and other parameter must compositive arrive in cutting tool, in order to make cutting tool fits specific treatment requirement. As a result of tap size range of pipe bent extensive, requirement each different, to achieve optimal cutting performance, design all sorts of different tap respectively with respect to need. Accordingly, tap should ask to design and be made according to specific treatment. In designing a process, answer to choose corresponding tap character according to need. Tap chooses different pulverous metallurgy high-speed steel normally (HSS-E) brand is made, these material can achieve the optimal combination of hardness, tall red rigid, wearability and tensile strength, attack to blind aperture especially for silk, because tap needs to cut bits in the excision when inverting, because this is right material performance demand is very high. The heat treatment means of tap depends on uses high-speed steel name and cutting tool utility, it is tap is made obtain the process with quality essential requirement. The geometrical appearance of tap should be designed according to workpiece material, want the part before the consideration not only, the horn after considering even. What differ with a lot of other cutting tool is, whorl tooth itself is the one part of appearance of cutting tool geometry. The control that the helix angle of tap helix chamfer sheds to cutting bits is crucial. Tap place also can be affected with coating cut bits to flow, still can be opposite at the same time the generation of the tumour that accumulate bits and heat in metal cutting are in workpiece, cut the conduction between bits and cutting tool to produce an effect. In treatment of high speed tap, the control of temperature becomes more important. Normally, the coating of tap and whorl figuration cutting tool uses Fu of PVD craft besmear, the annealing temperature that the deposit temperature of this craft expects under high-speed steel material. Tap machines example: On vertical CNC machining center, with the refrigeration inside area of German EMUGE corporation minimum lubricates (tap of coating of the collet of flexible and synchronous tap of MQL) function and EMUGE Rekord 2A-S TiCN, with the cutting speed of 60m/min, be in cast-iron (whorl of M14-6GX of the treatment on spare parts of GGG40) apply the brake. Figuration of whorl of 6 whorl form cutting (boil press figuration) it is craft of treatment of a kind of little bit. Whorl tooth be in controlling figuration process through boiling for many times, workpiece material produces displacement and form. Generally speaking, all shaping the workpiece stuff with good sex (show tensile strength is less than 1200N/mm2 normally, rupture percentage elongation is more than the material of 8% ) basically can use this method to machine whorl. Whorl form cutting can offer better than tap treatment quality whorl appearance normally, can avoid to discharge bits problem. Accordingly, it is recommended to be used at the thread machining of deep blind aperture and small diameter aperture especially. In whorl form cutting, must control strictly beforehand the aperture of aperture. Although bore diameter appears very little difference, because whorl is excessive,also can bring about cutting tool figuration and produce damaged. Of BMBF " dry cutting " project of research and development proved aluminous to casting material (the possibility that GK-AlSi9Cu3) has boiling pressing form cutting. Carry the comparative research of all sorts of pair of lubricant and system of lubricant feed flow, the conclusion that reach is: Lubricant presses form cutting to have very big effect to boiling. Use minimum to lubricate (the refrigeration inside MQL) boils press tap, can make machine torque value to be reduced with use the level with water radical almost same cooling fluid (the 1/3) that is worth to do cutting torque only. This consider to make clear, in whorl form cutting, replace pouring and cooling kind likely also with MQL technology. Example of whorl form cutting: On horizontal CNC machining center, use EMUGE firm inside cooling (20 Ba Shuiji cooling fluid) collet of flexible and synchronous tap and Ck-S-ÖL-IKZ-TIN-T1 of ü of EMUGE 2 Dr boil press figuration tap, with the cutting speed of 30m/min, in pull rod (material is × of M14 of the treatment on 42CrMo4V) 1.

5-7GX whorl. Nextpage7 synchronous tap (rigid tap) synchronous tap treatment is to show through numerical control means makes the axial of cutting tool and machine tool main shaft moves (compare normally slow) with whirligig (compare normally fast) keep synchronous, make the pitch line of whorl maintains the either part in blade of cutting tool cutting to go up from beginning to end thereby. The possibility that the accuracy that this kind of pitch moves reduced to produce whorl leakage to cut (this phenomenon often is considered as a diameter too big, but it is pitch interrupts) actually. Nevertheless, must undertake to machining motion rigor is monitored, even if,exist extremely small different step, also can arise to affect huge axial force to cutting tool. Force of this kind of axial will cause power of greater whorl flank attrition, accelerate cutting tool to wear away, make its easier invalidation. From the graph 10 can see quite great axial power, they are by initiative tap phase (when beginning cutting) the cutting power that produces gradually causes, and won't disappear in cutting process; Main shaft overspeed and the intrinsic error that synchronous tap circulates also can cause strength of this kind of axial. The collet of flexible and synchronous tap of EMUGE company can undertake compensating to load of this kind of axial, actually it basically is collet of a kind of rigid tap, but have in ± 0.

Undertake the smallest length is compensated inside 5mm limits (compress or drawing) function, can compensate the axial strength that main shaft overspeed and synchronous tap intrinsic error cause. The action of collet of flexible and synchronous tap resembles be located in the component of a damp between machine tool main shaft and tap, use at making up for the difference of pitch, too will great axial power and whorl cutting error reduce lowermost limit. It conduces to the other function of efficient thread machining still including: With use the fast track with rigid similar collet to jump precision; The PGR collet that carry pinchcock head or has square to coordinate a side is firm the ability of clamp tap. Collet of flexible and synchronous tap still applies to its main shaft to have the machine tool of function of internal feed flow. The cooling fluid that carries through in-house passageway (pressure can be amounted to 50 cling to) the axial starting a hole from tap or the Kongzhong that leave along the chamfer that discharge bits are ejective, but will cut bits to rush through whorl aperture, achieve optimal and lubricant result at the same time, improve treatment efficiency greatly thereby. Nevertheless, synchronous tap treatment also is meant, in whole tap process, cutting speed is change, and achieve rate of the biggest cutting impossibly also. Because the quality of its slide carriage is inertial with controller speed each are not identical, every machine tool has his specific damp trends character. Accordingly, because need the whorl deepness of treatment to differ, cutting speed also is changing from beginning to end. In addition, with treatment via photograph is compared, the main shaft when machining blind aperture needs to begin decelerate earlier. The cutting tool clip of 8 efficient thread machining runs PowRgrip system is a kind of extremely exact tap mix maintains pattern (to efficient thread machining especially such) . It uses system of a kind of mechanical clamp, realized large clamping force, fast track to jump precision, provide useful and same an ability that collet clip supports different measurement cutting tool. This kind of clip runs a system by a knife handle, tall accurate pinchcock first, and a cabinet machine composition that is used at inserting pinchcock head and cutting tool knife handle. This device inserts pinchcock head the active force of knife handle to exceed 6 tons, the clamping force that produces and shrinkage fitting collet are about the same, and do not have limitation to small size cutting tool, nonexistent also use high temperature heats up the dangerous sex when installing a system. Tolerancepublic errand can be without problem ground clamp for the tap handle of H9, change cutting tool needs a few seconds only. Still should point out, device of clamp of this kind of PGR is tightened with Yu Ga a few otherer cutting tool (like broach He Lixi knife) when, the effect is first-rate also. Use a very simple, device that uses easily, can undertake preliminary adjustments to the length of cutting tool. Tap of 9 high speed uses tap accessory device is a kind of when realize high speed tap effective solution. Generally speaking, use this method to be able to omit length compensates tap collet (among them compositive of machine tool main shaft invert functional) . Tap accessory device can come true to undertake high speed tap steadily. Compensate device through cancelling length, can realize tap effectively invert. Tap accessory device applies to M4 - the high speed treatment of M20 whorl. According to the size of whorl dimension, can use 1500 - the rotate speed of 3000r/min undertakes machining. This device is had inside function of cooling feed flow (cooling fluid is the biggest pressure 50 cling to) . Cutting tool uses pinchcock head clip to hold. The tap operation measure of tap accessory device and the operation move when using tap of groovy compensation collet or synchronous main shaft are similar. Nevertheless, an accepted difference is, method of this kind of tap is will machine whole whorl deepness with constant cutting rate, accordingly, its cutting condition keeps constant from beginning to end. This is opposite not only cutting / roll the treatment that presses tap position is favorable, and the cutting speed limits that still can keep away from to produce the tumor that accumulate bits likely. The device of SWITCH-MASTER tap accessory of EMUGE company has the following advantage: Can shorten significantly tap cycle time and treatment assist time, reduce finished cost; Constant cutting rate can provide longer cutting tool life; Can reduce a machine tool wear away and damaged, upkeep costs of economic machine tool and purchase cost; Constant power wastes OK and managing the sources of energy. The change of direction of rotation comes true through device of exterior and auxiliary pneumatic, its advantage is: The tap when gear inverting won't produce axial rock; Can make action falls at force of axial of tap whorl lateral to the smallest; No matter main shaft rotate speed is mixed whorl pitch how, can be close to sensor through, decide with extremely tall precision the inverting of gear is nodded. This function can ensure accurately treatment gives whorl depth; Because gear inverting way is shorter, the safe distance between workpiece and tap also can shorten, can shorten thereby tap cycle time; The sudden shift of direction of rotation can reduce gear inverting hardware wear away; Use complete oil bath to lubricate offerred run an environment smoothly with low tatty; Each other part the axial of tap accessory device and radial motion completely, can prevent cooling fluid thereby mutual leakage problem; Stop move clamping apparatus to be able to protect tap accessory plant, prevent the twist of likelihood happening, rise to transfer the function of auxiliary energy. Once stop,move clamping apparatus and machine tool type to be accorded with completely, allow to undertake changing a knife automatically; Use condition: Apply to the machine tool of CNC numerical control of electrified main shaft; Thread machining limits: M4 - M12; The biggest rotate speed: 3, 000r/min; Apply to right hand thread machining (function of left hand thread machining is optional) ; Type of applicable main shaft: The standard that adopts this device (interface of straight handle of DIN 1835 B+E) (diametical 25mm) , HSK, BT and CAT knife handle can apply to the tap treatment of this device; Refrigeration offers hydraulic pressure power inside: 50 cling to, optional match minimum to lubricate (MQL) function. 10 minimum are lubricant (MQL) tap to a lot of treatment, cool inside feed flow way is very good. Cooling tap has type of two kinds of basic designs inside: One kind is the IKZ that is used at blind aperture tap model (inside cooling aperture passes tap center) directly; Another kind is the IKZN that is used at via tap model (inside cooling Kong Tong crosses tap center, but exit is located in the) in discharging bits chamfer. To MQL tap, still have an additional demand. The changeover interface between machine tool main shaft and MQL tap collet, tap collet and cutting tool must avoid air impedance and depart of MQL gas mist. From fluid gas blends a dot to be exported to what stand by blade of cutting tool cutting, gas mist must flow in the conduit that close. To undertake compensating to tolerancepublic errand, interface place must deploy canal of bedspring to load, in order to ensure gas mist can be uninterrupted, flow without impedance ground. Monitoring of 11 treatment process is in efficient cutting (in HPC) tap or whorl form cutting, besides thread machining itself, very important also to machining the monitoring of the process. Use treatment process to monitor a system, conduce to undertake forecast and precautionary to its before all sorts of questions happen, shorten thereby the breakdown machine down time of the machine tool; Cutting tool can use his till real life is terminative, and need not change a knife by the thread machining number that sets beforehand; Even if is the treatment with greater difficulty, handlers also need not total value is defended, make one person in charge of much thereby stage machine tool and even " light-off is produced " become a possibility. The DDU system of EMUGE company is on tap collet inside buy has a sensor, the treatment power through will be being explored and data output change convey to be not contact signal receiver, can at the same time, real time ground detects a tap torque and axial force. This system still can explore the damaged of cutting tool or be short of break, beforehand aperture is short of break, whorl deepness is not complete wait for blemish, it still can detect the cutting tool that in machining a process, increases gradually wears away, make thereby accurate cast cutting tool life, and use cutting tool life terminative (before cutting tool damaged) become a possibility. Can shorten so be not handling time, and the main component that this is efficient treatment whorl. DDU system still can is opposite the data of every time thread machining has record and file, this one function is very useful to assuring to machine quality. Every time thread machining each are not identical, undertake be metricaled first through new to knife, can distinguish this differentia different. Next, the axial force that can machine the generation in whorl process to cutting tool and cutting torque undertake observation and monitoring, as the accretion of cutting force, can detect in real time of cutting tool wear away state. Of 12 whorl detect of level of management of quality of ISO 9000 series carry out increased to detect the importance with quality of product of test and verify. In thread machining, this job includes what already machined whorl to be opposite detect, and the measurement of the whorl gauge to been use and calibration. The parameter of a few whorl that need detects includes: ① pitch; ② screw center diameter; ③ trail; ④ old way; ⑤ is homocentric degree; ⑥ taper; ⑦ tooth horn. The measurement of whorl can use a variety of methods inside, if measured a way at 3 o'clock. This method uses to install the double head form on length measurement unit to measure a head to undertake metrical. L of Δ of the distance that be measured is the position that measure a head 1 arrive the distance of 2 and the 1 arithmetical average to the distance of 3. 3 all contacts are nodded whether all is located in same and columnar face (whorl axes) it is not important to go up. If can aim whorl axes completely, measured a way at 2 o'clock (need to touch only measure 1 and 2 at 2 o'clock) also can satisfy gauge a demand. M is to measure on the head two end to measure the center of the ball to be apart from () of the constant that measure a head. Use a few formula to have consideration to measuring data, with respect to can affirmatory screw center diameter. When computation, need considers to measure profile of ball diameter, whorl, and even the deflection that measures a ball to fall in the action that measure power. What measure so is screw center diameter only, the trail to obtain whorl, old way, homocentric spend or whorl profile, still need to undertake other measure. In actual production, a kind quicker, more practical inside whorl detects the method is to use whorl gauge (stop compasses) . Whorl gauge detects OK and quickly, handily and evaluate all sorts of whorl parameter (be like pitch, diameter, profile, homocentric degree, the) such as taper, of the spare parts in ensuring sequel rigs process thereby cooperate precision, avoid to extend the nonproductive time of ship-fitter foreword because of whorl quality blemish. The calibration of 13 whorl gauge uses the whorl gauge that passes calibration only, the effectiveness that ability assures to whorl detects. Already wore away or make the miscarriage of justice of didymous whorl quality. By book cycle to undertake to gauge desired result can assure to detect the validity of the result. Desired result means includes to undertake metrical to gauge not only, still include with more the standard of high-level class undertakes comparing is opposite. To realize the calibration of whorl gauge, a very fundamental premise condition is to have what deliver continuously to trace to the source method. Metrical traceability is to point to adopt form of layer of one or more quantity value transfer, will one relevant the metrical value that be measured and corresponding country are fiducial undertake comparing is opposite. In each layer class, want to will measure instrument and uncertainty deviation smaller, belong to more of high-level class measure fiducial undertake comparing is opposite. Measure standard layer level taller, the uncertainty that its measure is less. Common experience law is: On one class measures fiducial uncertainty to measure the 1/3 of fiducial uncertainty to issue one class about. A give typical examples of class of layer of quantity value transfer: Ground floor class is a country fiducial (the NIST) of the PTB that is like Germany or United States; The 2nd class is attestation calibration lab fiducial; The tool room that three-layer class is an enterprise is standard; The 4th class is a workshop fiducial. Gauge and the calibration that measure an instrument are in independent calibration the lab undertakes normally. Use relevant software, can be opposite the calibration cycle of gauge, measure a result to wait undertake dogging effectively administrative. Efficient thread machining just does not need 14 brief summary raise cutting rate, must undertake optimizing upgrading to whole technological process however. Must use appropriate HPT cutting tool, wait for photograph union with parameter of cooling and form of proper cutting tool geometry, coating, lubricant system, machine tool; In addition, still must undertake close monitoring to machining a process, undertake detecting accurately to machining a result. In a word, to realize efficient thread machining, must abide by the following 10 principles: Choose plan of optimal thread machining according to machining the task (tap / boil press figuration / whorl milling) ; According to workpiece material and treatment requirement, use appropriate cutting tool data and geometrical figure; Choose proper craft parameter; Choose appropriate tap collet and cutting tool clip to maintain pattern; The choice accords with the cutting tool coating that machines a requirement; Ensure workpiece installation is correct, machine tool stiffness is enough; The cooling and lubricant means with applicable consideration (pouring style is cool / ) of the refrigeration inside MQL/ high pressure; The whorl gauge of use course calibration detects whorl; Use treatment process monitoring; Ensure all right combination that choose a function (for example: MQL is lubricant + MQL collet + MQL tap) . CNC Milling CNC Machining