Application analysis of HSC end mills and tool holders in five-axis machining molds

In order to improve mold processing efficiency and reduce manufacturing costs, five-axis machining centers and five-axis CAM processing technology can be used. Its advantages are the ability to select the best processing conditions, improve processing accuracy and processing quality, and achieve process intensiveness. To achieve this goal, optimized high-precision tools and high-performance tool holders (or tool holders) are indispensable elements. The following briefly introduces high-speed cutting (HSC) carbide end mills and powRgrip powerful clamping tool holders.

(1) HSC carbide end mill

HSC carbide end mills have excellent performance and can significantly reduce processing costs. It can give full play to the functions of the five-axis machining center during high-speed milling, and greatly shorten the processing time.

HSC cemented carbide end mills have the following characteristics: ①high-performance cemented carbide matrix; ②cutting edge for stable high-speed milling; ③TiAlN coating with high heat resistance; ④the diameter of the tool neck is smaller than the shank Part diameter; ⑤ Tool holder accuracy: h5; ⑥ End mill outer diameter accuracy: φ8mm or less: 0～－0.02mm; φ8mm or more: 0～－0.04mm; Ball nose radius accuracy: ±0.01mm; ⑦It can mill HRC66 and All workpiece materials with the following hardness; ⑧φ16mm end mill has 16 teeth at most.

(2)powRgrip strong clamping of the tool holder (Guide: Analysis of common misunderstandings in the EDM process of enterprises)

In order to give full play to the machining performance of HSC carbide end mills, it is very important to improve the rigidity and accuracy of the tool holder, which is also one of the issues to achieve high-level mold processing. The newly developed PowRgrip powerful clamping tool holder is a high-rigidity and high-precision tool clamping system. It hydraulically presses a spring chuck with a small taper into the tool holder to achieve tool clamping, which solves the heat in the past. The long time of press-fitting tool, the limitation of the material of the tool shank, and the short life of the tool shank have improved the rigidity and run-out accuracy of the tool shank.

powRgrip strong clamping tool holder has the following characteristics:

①Short tool change time (less than 10 seconds); ②Long repetitive service life (20,000 times); ③Large tightening torque (φ20mm shank: 380Nm); ④High radial jump accuracy (below 3μm); ⑤Clamp The holding performance has nothing to do with the material of the tool; ⑥The tool holder overhang adjustment accuracy is high (within 10μm); ⑦The ability to absorb cutting vibration is strong.

Processing example: Milling S45C carbon steel with a φ16mm end mill, the speed is 6000r/min, and the feed per tooth is 0.1mm. The machined surface roughness Ra of the hot press fitting fixture, hydraulic fixture and powRgrip tool holder were tested respectively. The results show that compared with the hot press fitting fixture, the tool life of the powRgrip tool holder is increased by 180%, which is converted to Tool costs can save 44% of costs.

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