How to control the milling effect of high hardness materials in CNC machining?
How to control the milling effect of high hardness materials in CNC machining?
There are many factors involved in the success of hard milling. Today, let's take a look at some of them.
The first important factor to consider in hard milling is the structure of your machine tool. So in order to achieve the desired effect of hard milling, we first need a very solid machine with high damping capacity.
In general, machines made of polymer concrete have the cushioning capacity of many machines made of cast iron. At the same time, it is also important to have CNC controllers capable of handling the dynamic requirements of constant and rapid acceleration and deceleration!
The next thing I want to talk about is the holding of the spindle and the cutter. These are two very different things, but they are related to each other in use.
First you need a rigid rotor! If your spindle beats, the most concentric and best handle in the world will only help you. That said, combining high-speed spindles with the best cutting tools can yield results you didn't expect.
The HSK series is one of the most popular handles for hard milling because its interface with the spindle increases rigidity and concentricity.
The spindle and tool holder of hard milling should be selected according to the rigidity and low beat. In the process, we found that HSK's tool holding system is very effective!
Of course, we should not forget the tools themselves. We also did some research and found that there are a number of mold manufacturers that specialize in custom-made tools for hard milling. But we cannot be too credulous about these parameters. Most of these mold makers have experts who can help choose materials and specific machining tools, and we can take full advantage of these services to save us time and increase efficiency. At the same time the cutting tools selected for hard milling applications must be coated to withstand the high heat and extremely high friction associated with these materials.
And these tools probably aren't cheap! So, if you ask your boss for an end mill and the price is higher, you can give him so many advantages to justify the purchase. Plus, if you need to buy two, you can ask for four. That way, when he asks to buy just two, he'll also feel like he saved the company money.
Back to the subject. CAD/CAM software is the last piece of the puzzle (not really, the puzzle will never be missing). Programming software is one of the most important considerations in hard milling. It can control the load on the cutter. You want the loading of the cutting tool to be free of impact, which means that the cycloid milling is done sequentially or, as is often said, dynamically. The principle behind dynamic milling related to hard milling is that your cutter can easily and consistently join the material. No sharp jumps, smooth forces. Most major CAD/CAM packages now have some form of dynamic milling.
Just like using these tools and strategies in a machine shop, garage, or anywhere else, knowledge is power. We need to acquire higher processing skills through continuous learning.