(I) Pay attention to the material and brand
The material and brand of tungsten steel milling cutters have a decisive influence on their performance. Generally, imported carbide materials are often superior to domestic materials in quality and performance, and the price is relatively high, generally 2-3 times that of domestic materials. Different brands also have large differences in composition and performance, and the price will naturally be different. Take YT15 brand tungsten steel as an example. It contains 15% titanium carbide (TiC), has high hardness and wear resistance, and is suitable for processing tough materials such as steel; while YG8 brand tungsten steel has a higher cobalt content and better toughness, and is more suitable for processing brittle materials such as cast iron and non-ferrous metals. When choosing a tungsten steel milling cutter, it is necessary to carefully select a milling cutter of suitable material and brand according to the specific processing materials and processing requirements to ensure the processing effect and tool life.
(II) Check the appearance details
Appearance details are an important basis for judging the quality of tungsten steel milling cutters . First of all, check whether the angle of the tool is accurate, which is directly related to the cutting performance and processing accuracy of the milling cutter. Milling cutters with inaccurate angles may have problems such as uneven cutting force and increased tool wear during the cutting process, affecting the processing quality. Surface finish is also an important indicator. The surface of a high-quality tungsten steel milling cutter should be smooth and bright, without obvious flaws and scratches. The laser printing should be clear and complete, and can accurately reflect the brand, model, specifications and other information of the tool. The front end of the milling cutter should be flat, and the teeth should be neat and uniform, without chipping, missing teeth and other phenomena. The back angle blade should be uniform and consistent, and there should be no obvious differences. At the same time, carefully check whether the tool has defects such as burrs and cracks. These defects will seriously affect the strength and service life of the tool, and may cause the tool to break suddenly during use, causing safety accidents.
(III) Consider clamping and vibration factors
The clamping method and vibration of the end mill have an important impact on the processing process . At present, most end mills used in machining centers are clamped by spring clamp sets and are in a cantilever state when in use. During the milling process, the end mill may sometimes gradually extend from the tool holder or even fall off completely. This is usually because there is an oil film between the inner hole of the tool holder and the outer diameter of the end mill shank, resulting in insufficient clamping force. In order to avoid this situation, before clamping the end mill, the end mill shank and the inner hole of the tool holder should be cleaned with cleaning fluid, and then clamped after drying. When the diameter of the end mill is large, even if the shank and the tool holder are very clean, the tool may still fall off. At this time, a tool holder with a flattened notch and a corresponding side locking method should be selected to ensure that the tool is firmly clamped.
There is a small gap between the end mill and the tool holder, which may cause the tool to vibrate during processing. . Vibration will make the cutting amount of the circumferential edge of the end mill uneven, and the cutting expansion amount will increase compared with the original value, affecting the processing accuracy and tool life. When the width of the processed groove is too small, the tool can be vibrated purposefully to obtain the required groove width by increasing the cutting expansion amount, but the maximum amplitude of the end mill should be limited to less than 0.02mm, otherwise stable cutting cannot be performed. In normal processing, the smaller the vibration of the end mill, the better. When tool vibration occurs, consider reducing the cutting speed and feed speed. If both have been reduced by 40% and there is still a large vibration, consider reducing the cutting amount. If the processing system resonates, it may be caused by factors such as excessive cutting speed, low feed speed, insufficient rigidity of the tool system, insufficient clamping force of the workpiece, and workpiece shape or workpiece clamping method. At this time, measures such as adjusting the cutting amount, increasing the rigidity of the tool system, and increasing the feed speed should be taken to reduce the impact of vibration on processing.
VI. Guide to correct use and maintenance
(I) Preparation before use
Before using tungsten steel milling cutter, be sure to conduct a comprehensive and detailed inspection. First, carefully check the appearance of the tool, check whether the teeth are chipped or missing, and whether there are cracks on the surface of the tool. These defects will not only affect the processing quality, but may also cause the tool to break suddenly during use, causing safety accidents. At the same time, check whether the coating of the tool is uniform and complete. The quality of the coating is directly related to the wear resistance and cutting performance of the tool.
Correct installation is also crucial. Ensure that the connection between the shank and the milling cutter is tight and firm, and the concentricity is good. During the installation process, strictly follow the operating procedures to avoid vibration or swing of the tool at high speed due to improper installation, which affects the processing accuracy and surface quality. Before installing the tungsten steel milling cutter on the machine tool spindle, clean the mating surfaces of the shank and the spindle to remove oil, impurities, etc. to ensure good contact.
(II) Reasonable selection of cutting parameters
Cutting speed, feed rate and cutting depth are key parameters that affect processing quality and tool life. The cutting speed should be reasonably selected based on factors such as the hardness of the processing material, the material and diameter of the tool. For materials with higher hardness, such as hardened steel, the cutting speed should be appropriately reduced to avoid the tool from being worn out due to overheating; for materials with lower hardness, such as aluminum alloy, the cutting speed can be appropriately increased to improve processing efficiency.
The selection of feed rate should comprehensively consider the number of teeth of the tool, the strength of the cutting edge and the roughness requirements of the processed surface. A larger feed rate can improve processing efficiency, but it may increase the roughness of the processed surface and accelerate tool wear; a smaller feed rate can obtain better surface quality, but the processing efficiency will be affected. In actual processing, it is necessary to adjust according to the specific situation.
The cutting depth should be determined according to the rigidity of the tool, the power of the machine tool, and the material and structure of the workpiece. Excessive cutting depth may cause the tool to bear excessive cutting force, resulting in tool damage; too small cutting depth will reduce processing efficiency. Generally speaking, in rough processing, a larger cutting depth can be selected to quickly remove most of the excess; in fine processing, a smaller cutting depth should be selected to ensure processing accuracy and surface quality.
(III) Key points for daily maintenance and maintenance
After each use, the tungsten steel milling cutter should be cleaned in time. Use a special cleaner and a soft brush to remove chips, oil and other impurities on the surface of the tool. Pay special attention to cleaning the gaps between the teeth to prevent chips from remaining and affecting the next use of the tool. Avoid using hard objects to scratch the surface of the tool to avoid damaging the coating and cutting edge of the tool.
Regularly lubricating the tungsten steel milling cutter can reduce the friction between the tool and the workpiece, reduce the cutting force, and extend the service life of the tool. Choose a suitable lubricant and apply it according to the prescribed method and dosage. Lubricant should also be applied appropriately to the contact part between the tool handle and the tool holder to ensure the clamping accuracy and stability of the tool.
Store the tungsten steel milling cutter in a dry and ventilated environment to prevent the tool from getting damp and rusting. You can use a special tool box or tool holder for storage, and classify the tools to avoid collisions. For tools that are not used for a long time, anti-rust oil should also be applied to the surface to further protect the tool.
Looking to the future, with the continuous upgrading of the manufacturing industry and the rapid development of science and technology, tungsten steel milling cutters will usher in a broader development space. Under the wave of intelligent manufacturing and Industry 4.0, the demand for high-precision and high-efficiency processing will become more urgent. As a key processing tool, the performance and quality of tungsten steel milling cutters will continue to improve. In the future, tungsten steel milling cutters are expected to make greater breakthroughs in material innovation, coating technology, and tool design to meet increasingly complex and diverse processing needs.
In terms of new material research and development, scientists will continue to explore and optimize the composition and structure of tungsten steel, further improve its hardness, wear resistance and red hardness, so that it can also handle more difficult materials with ease. At the same time, the application of new coating technology will bring better lubricity, corrosion resistance and high temperature resistance to tungsten steel milling cutters, effectively extend the service life of the tool and improve processing efficiency.
Tool design will also be more intelligent and personalized. Through advanced computer-aided design (CAD) and simulation technology, the most suitable tool shape and parameters can be accurately designed according to different processing tasks and material properties, and customized production of tools can be realized. This can not only improve processing accuracy and quality, but also reduce production costs and improve production efficiency.
In addition, with the enhancement of environmental awareness, the manufacture and use of tungsten steel milling cutters will also pay more attention to environmental protection and sustainability. Adopting green manufacturing processes, reducing energy consumption and waste emissions, and recycling and reusing waste tools will become an important direction for the future development of the industry.
As an important tool in the field of industrial processing, tungsten steel milling cutters have made important contributions to the development of the manufacturing industry with their excellent performance and wide application. In the future, we have reason to believe that tungsten steel milling cutters will continue to play their key role, continuously promote the manufacturing industry to a higher level, and inject new vitality into the development of global industry.
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Contact us:Company name:Kunshan Meiyaxing Hardware Machinery Co., Ltd;Tel:8618962438699;Address: Room 3003, Building 3, Zhengtailong, No. 1288 Chengbei Middle Road, Kunshan City, Jiangsu Province, China;Email:myxcuttingtools@gmail.com;Website: https://www.myxcuttingtools.com
