Titanium alloy efficient machining cutting tool.
The cutting workability of titanium alloy is poor, and the cutting speed of traditional processing methods generally doesn't exceed 60m/min. The rough machining of titanium alloys mainly uses the method of large depth of cut, low speed and low feed to obtain the maximum metal removal rate. PVD coated carbide cutting tools are used for finishing for high-speed milling with small cutting width and large cutting depth to obtain efficient cutting. Therefore, titanium alloy machining tools mainly focus on how to avoid chattering, reduce cutting force, and reduce cutting temperature during strong cutting:
(1) Titanium alloy face milling:
When face milling titanium alloy parts, milling with small depth of cut and large feed is used to obtain efficient processing. The principle of high-feed milling is to reduce the tool's main deflection angle, so that the tool can still maintain a small chip thickness under high feeds, so as to reduce the cutting force at high feeds and achieve low cutting speed, a large feed is obtained, increasing the metal removal rate per unit depth of cut. At the same time, the cutting force part is vertically upward, the tangential force is small, and the power consumed is also small. This processing method does not require high power and rigidity of the machine tool, and is widely used.
(2) Titanium alloy cavity processing:
Slot cavity is a main feature of titanium alloy aerospace structural parts. The material removal rate is high and the workload is large. Therefore, slot cavity processing is the key to the efficient processing of titanium alloy parts. Strong cutting with large cutting depth, low speed and low feed to obtain maximum metal removal rate is an effective method for roughing titanium alloys. At present, the powerful milling tools for rough machining titanium alloys are widely used with the highest efficiency of corn milling cutters.
(3) Fillet processing technology:
In order to reduce the weight of the aircraft, the fillet at the corner of the groove of the aircraft structure is usually small, and a milling cutter with a smaller diameter is required for processing. Due to the abrupt cutting amount at the fillet, the cutting force varies greatly. In the case of abrupt cutting force, the tool easily generates vibration and even chipping, which results in severe tool wear and low machining efficiency. Plunge milling is the best way to solve the corner processing efficiency. The plunge milling process has less vibration than conventional milling, and the cutting method has a high efficiency in removing the corner allowance. Inserting and milling at the corners by inserting and milling tools with different diameters can remove most of the remaining margin of the corners, and then use the end mill to remove the residue generated by inserting and milling, which can greatly improve the processing efficiency.
(4) Precision side milling technology:
When finishing the side wall, the interruption of milling is used to achieve the purpose of high-speed cutting to improve the surface quality and processing efficiency of the part. When finishing the side, due to the small cutting width, the cutting time for each revolution of the cutter teeth is very short, that is, the cooling time is very long. In the case of sufficient cooling, the cutting temperature can be effectively controlled, so the cutting speed can be greatly increased to improve the processing efficiency.High-speed cutting and finishing of titanium alloys can greatly improve machining efficiency and precision.
(5) Simulation optimization technology:
The cutting allowance of titanium alloy structural parts will change continuously during rough machining. The NC program compiled by the current CAM software can only set fixed cutting parameters. In order to avoid the impact of the local program on the tool and the machine due to the excessive cutting amount, the general method is to reduce the overall cutting parameters to ensure tool life and part quality Therefore, the processing efficiency is extremely low. Vericut's simulation optimization technology can solve this problem well. The cutting parameter optimization library is set by Vericut software, and the software is used for simulation. The actual machining allowances and cutting conditions are guessed through the simulation, and the cutting parameters in the program are optimized according to the machining allowances and cutting conditions. Not only extends the tool life, guarantees the quality of the parts, but also improves the processing efficiency.
