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Road Milling Tools Processing High Hardness, High Abrasiveness
- Jun 28, 2017 -

As manufacturers continue to introduce products with more features and higher performance, the components that make up these products are becoming more and more complex, and their manufacturing is becoming more and more difficult. In addition to complex surface profiles and increasingly stringent dimensional tolerances, these components are often made of high-performance materials with good strength and reliability, and these material properties adversely affect their cutting performance.

Tool manufacturers are also constantly developing new tools that maximize processing efficiency. The technological advancement of Road Milling Tools is an example of this effort. For a long time, the overall carbide cutter provides users with a high metal removal rate and excellent machining accuracy. However, the integration of such tools determines the need for grinding after they need to re-grinding. Replacing the tool will disrupt the production process and spend a lot of time and money. In addition, the use of re-grinding of the milling cutter need to modify the parameters of CNC machining procedures, and in order to process different parts profile, you may need to choose a more suitable tooth type of different types of milling cutter.

As a better alternative to the overall cost of the milling cutter, the tool manufacturer has developed a cutter that can be indexable and replaceable blades. When the blade cutting edge wears, simply divert the blade to the new cutting edge. When the blade cutting edge is completely worn out, it is possible to quickly replace the blade without having to remove the cutter body from the machine tool, and attach the blades with different geometries on the same cutter body to suit the contours of the different parts need.

Positive rake angle with negative rake cutter

The geometries of indexable inserts are also evolving. Many of the indexable inserts have a cutting edge on the top and bottom of the blade. After this double-sided blade is turned, it can be turned over to the other side, and the number of available cutting edges is doubled. However, the design of the double-sided blade does not include the inclination angle of the blade body after the cutting edge, so that the cutter can not be cut by the front rake angle.

In the front rake cutter, the main body of the blade is tilted rearwardly from the cutting edge so that the cutting edge can shear the workpiece material. In contrast,Road Milling Tools the negative front horn cutter blade is tilted to the workpiece, the cutter is basically in the push of the cutting material. The design features of the double-sided blade determine that the cutting edge must be close to the workpiece at a negative angle.

Negative rake cutter can provide some benefits: they have better strength, can withstand greater chip load and cutting force, so more suitable for rough milling, intermittent cutting and processing of high hardness, high abrasive workpiece material (Such as cast iron). As a result of the use of multi-cutting blade can reduce the cost of the tool, so easy to work in the workpiece material for simple two-dimensional milling, double-sided negative blade is a good economy with a choice.

However, since the negative front horn cutter is primarily pushed (rather than shearing) the working material, it will produce a large amount of cutting force and a large amount of cutting heat. If the machine's power is low or the rigidity of the entire processing system is insufficient, it will adversely affect the final machining accuracy. For example, the cutting force generated by the negative rake cutter may distort the thin-walled workpiece.

In contrast, the positive rake cutter achieves free cutting, minimizing the cutting pressure, and often milling the negative profile of the negative front horn cutter that can not be reached. The positive blade edge has excellent machining flexibility and can be used to perform a variety of different machining applications, including milling, profiling, helical milling and slope milling. It is important to reduce the cutting force as much as possible when milling difficult-to-machine materials such as titanium alloys,Road Milling Tools Inconel alloys and a variety of stainless steels on old machine tools or rigid machine tools, while using the front rake cutter helps to improve processing stability Sex.

Single blade

In order to provide an indexable insert that can be milled in a positive angle mode, the tool manufacturer has developed a single-sided blade with a certain rearward angle after the cutting edge. Although this blade can not be turned on both sides of the use, but can rotate on the knife seat, providing a number of effective cutting edge.

The free cutting characteristics of the front horn milling cutter can reduce the cutting force and the cutting heat generated during cutting, thus prolonging the tool life. This is important because the life of each blade must be three times the life of the blade per blade in order to achieve a cost-effective equivalent.

Geometric blade type design

In addition to the basic differences between the positive and negative cutting edges, the tool manufacturer has developed a variety of different blade configurations to meet the need to maximize productivity when processing different workpiece materials. For example,Road Milling Tools in the milling of soft materials (such as free-cutting aluminum alloy), the use of very sharp, uncoated fine grinding cutting edge can get a good processing effect.

For workpieces that are more difficult to process (such as steel, cast iron, or stainless steel), it is necessary to prepare (pass or chamfer) the tool edge in order to prevent chipping. For example, blade edge fabrication for processing cast iron typically involves grinding a negative chamfer and cutting the edge about 30-35 μm in size. The inserts used to process Inconel alloys and titanium alloys require geometrical grooves that are more suitable for free cutting, and their edges are fabricated without chamfering, but are cut in pass by about 20-25 μm in size.