Cutting speed affects tool wear
The temperature of the cutting zone and the associated tool wear are particularly affected by the cutting speed. When cutting titanium metal, the increase of cutting speed, in addition to affecting the cutting performance, will also greatly reduce the service life of the tool. If the feed rate is also increased at the same rate as the cutting speed, the tool life will only be slightly reduced. At first glance, it seems that increasing the feed rate is an attractive way to increase the cutting rate. However, as long as the great cutting force generated at high feed rates and its negative impact on chip management are observed, it can be seen that this approach is not worth recommending.
High pressure cooling measures can help. It not only helps to increase the cutting speed, but also does not cause the temperature to rise, and at the same time can reduce the increase of the cutting force at a higher feed rate. When machining ISO-S materials, the cutting speed can be increased by 20% with the same cutting length.
When using drill rods to machine larger and deeper holes, a modular tooling system such as Coro-TurnSL can be combined with HPC to better realize its advantages: the cutting head is not limited by the drill pipe. Quick and easy free replacement, so you can flexibly perform multiple machining steps. The use of high pressure cooling lubricants allows for a more controlled chip shape and reduced shearing. This allows the machining operation to reach a safe and wear-free level. The Coro-TurnSL system combines a vibration-damped drill pipe with a stable cutting head tool interface. This combination is suitable for drilling operations with a hole diameter up to 10 times the diameter of the drill pipe and is equipped with a connection to the high pressure cooling system.
Coro-Mill690 sleeve end mills are specially prepared for high pressure coolant
HPC also has its advantages when milling high-strength materials. The Coro-Mill 690 system is a sleeve end mill with high pressure coolant function developed for the processing of titanium alloys. Each indexing insert has its own coolant introduction system, so each insert benefits from the benefits of high pressure coolant jets. If the milling cutter does not need to be fully buried, the unactivated coolant introduction system is closed to keep the coolant pressure from being lost. The positional distribution of the coolant nozzles on the end faces of the milling cutter takes into account the convenience of chip evacuation and avoids the secondary cutting of the chips, especially when machining recesses and grooves and inconvenience in chip discharge.
The computer determines the ideal HPC parameters
Since titanium is a material that is prone to reaction and has a tendency to nodulate on indexable inserts, this phenomenon can lead to a sharp decrease in tool life. In this regard, the solution is also to use high-pressure cooling technology, which can effectively prevent the formation of knife-edge nodules.
The ideal HPC parameters can be determined using a dedicated computer. It is necessary to enter values ​​such as coolant flow rate, coolant pressure value, cutting value, axial depth of cut, and tool characteristic parameters. The results of the measurements can provide recommendations and basis for the selection of the optimum nozzle size, and the optimal nozzle selected can maintain a lower coolant flow while maintaining the coolant at a constant pressure.
Temperature changes and cutting forces generated during processing can cause fluctuations in surface quality. Since conventional cooling methods have helped to improve the surface quality of the workpiece, the use of high pressure coolant can greatly affect the results of the final finishing. The coolant jet can be accurately aligned to a specific location on the blade that is in contact with the finished surface, and accurate orientation avoids jet deviations and possible sources of error. This results in a safe and homogeneous processing process for flawless surface quality.
However, the use of high pressure cooling lubricants does not compensate for errors in other application parameters (eg, wrong indexing inserts, unstable machining, or incorrect cutting data). Under other correct baseline conditions, HPC is undoubtedly a “cutting process optimizerâ€. High-pressure cooling technology provides opportunities and conditions to reduce process time, maintain consistent quality of the workpiece, and improve the safety of the car and milling process.
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