High demand for cutting tools for mold processing

Head end mill has theoretical cutting residual parts, especially the end horizontal blade with low cutting speed is prone to breakage. The rounded end mill can often form a certain cutting surface when processing, so it has the advantages of stable and reliable processing.

The Epoch deep cutting rounded end mill, which is now developed, is able to prevent chatter generated during deep cutting. In order to further improve the processing efficiency, the inverted cone design is adopted. This design prevents the peripheral edge from contacting the cut material due to tool bending during the cutting process, thus achieving stable processing. In addition, the tool coating adopts TH with high hardness and high heat resistance and wear resistance (TiSiN) Hard coating, very suitable for direct deep cutting of high hardness material.

The following features of Epoch deep cutting rounded end mill are introduced through machining examples.

(2) Processing example

① efficient processing example of trench

in order to efficiently process the groove, the step distance in XY direction needs to be increased to a certain extent, however, if the ball end mill is used to process, the center edge that cannot improve the cutting speed will bear a lot of load and have to reduce the cutting conditions.

as can be seen from the results of machining the groove using the ball end mill: if the set XY step distance is increased, the damage degree at the center Edge will also increase; If the set XY step distance is reduced and the cutting conditions are reduced, although the center edge is not observed to be damaged, the wear of the front-end Center horizontal edge is increased. From the results of using Epoch deep cutting rounded end mill to process the groove, it can be seen that not only the cutting is stable, but also the wear is reduced, and the high hardness (About 50 HRC)The groove processing effect of hot die forging steel workpiece is good.

In this processing example, the processing time required for the new rounded end mill is reduced by about 1/4 compared with the ball end mill, and the processing cost is reduced by more than half.

② deep cutting of high hardness materials

SKD11 cold working die steel was processed from long-neck end mill (60HRC) As can be seen from the results, the peripheral cutting edge of the ball end mill is very damaged; The Epoch deep processing rounded end mill is not damaged, only uniform wear. It can be inferred that due to the large contact length of the cutting edge of the ball end mill, the cutting resistance is also large, and the peripheral cutting edge with high cutting speed is easily damaged. This is the same as example ①, and the rounded end mill has obvious advantages.

can be seen by the comparison of the rounded end mill of Hitachi tools with the rounded end mill of other companies under the same processing conditions, the rounded end mill produced by other companies does not adopt the inverted cone design, which is not ideal for the processing of high-hardness materials exceeding 60HRC. The new generation of deep cutting fillet end mill of Hitachi tools, because of the unique design of the anticlinal shape, the peripheral cutting edge is point-contact cutting, even when processing high-hardness materials with straight cutting method, the cutting resistance is very small, and the processing state is stable.

The machining example of Epoch deep cutting rounded end mill shows that the tool has excellent performance, especially when deep cutting of high hardness materials. In short, give full play to the role of rounded end mills, which can directly process the materials after heat treatment and quenching, and greatly reduce the processing cost due to the shortening of the processing process. Experiments show that the processing efficiency of rounded end mill can be increased by more than 5 times, and the processing cost can be reduced by 35%.

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