Maintenance and maintenance of turning tool blades
(I) Installation points
The installation of turning tool blades is the primary link to ensure its normal cutting performance. Accurate installation can effectively improve processing accuracy and efficiency and extend the service life of the blade.
Before installation, be sure to carefully check whether the blade has defects such as chipping and uneven wear. If there is a problem, it should be replaced or repaired in time to avoid affecting subsequent processing. At the same time, the installation surfaces of the tool bar, tool pad and blade should be wiped clean, and the burrs on the gasket and the hole should be removed to ensure that the installation position is accurate and correct, so as to avoid blade installation deviation caused by dirt and burrs, thereby causing changes in cutting angles and reducing processing quality.
During the installation process, the length of the turning tool extending out of the tool holder must be strictly controlled, and generally should not exceed 2 of the tool bar thickness. times, the extension length of the grooving knife and the cutting knife should also follow the corresponding standards to avoid the weakening of the tool bar rigidity due to excessive extension, vibration under the action of cutting force, and greatly reduce the surface finish of the workpiece. In addition, the tip of the turning tool must be accurately aligned with the center of the workpiece. Too high or too low will cause the turning tool angle to change. The adjustment of the tip height during rough turning and fine turning should be finely operated according to the diameter of the workpiece to ensure stable cutting. The gasket used to install the turning tool should be flat and smooth. Try to use thick gaskets to reduce the number of pieces. Generally, 2-3 pieces are appropriate, and each gasket should be neatly placed directly under the tool bar, with the front end aligned with the edge of the tool holder to prevent the turning tool from vibrating. Finally, when tightening the tool holder screws, use a special wrench to tighten them one by one in rotation to ensure that the screws are evenly stressed and reliably tightened to prevent the blade from loosening and moving during processing.
(II) Wear monitoring
In the process of mechanical processing, it is very important to monitor the wear condition of the turning tool blade in real time. This is like equipping the processing process with an accurate "health doctor" who can detect the blade in time. "Health issues" ensure smooth processing.
Direct observation of the appearance of the blade is the most basic method. Use the naked eye or a magnifying glass to carefully check whether the blade is worn, chipped, rolled, etc., as well as the width and color changes of the wear band on the back face. For example, a normally worn blade will gradually become less sharp, the wear band on the back face will widen as the cutting time increases, and the color may also change due to cutting heat. Once these signs are found, you need to be alert to the degree of blade wear.
Measuring the dimensional accuracy and surface roughness of the workpiece is equally critical. If the dimensional deviation of the processed workpiece exceeds the tolerance range, or the surface roughness value increases significantly, it often means that the blade is severely worn and cannot meet the processing requirements. In the turning of precision shaft parts, as the blade wears, the diameter tolerance of the shaft may expand from ±0.05mm to more than ±0.1mm, and the surface roughness deteriorates from Ra0.8μm to Ra3.2μm, then you must consider replacing or regrinding the blade.
Monitoring with the help of advanced instruments and equipment is more accurate and efficient. For example, the use of acoustic emission sensors can keenly capture the tiny elastic waves generated by the blade during the cutting process due to wear and chipping. By analyzing the characteristic parameters of the acoustic emission signal, the wear state of the blade can be judged; the cutting force dynamometer can monitor the changes in cutting force in real time. When the blade wear increases, the cutting force will increase accordingly. According to the fluctuation of the cutting force, the degree of blade wear can be grasped in time, providing a scientific basis for tool replacement.
(III) Timing of regrinding and replacement
Knowing when to regrind or replace the turning tool blade is a key decision point to maintain processing accuracy and efficiency. Too early or too late may bring adverse consequences.
Generally speaking, when the wear band width of the blade back surface reaches a certain value, it is necessary to consider regrinding or replacement. For carbide blades, if the wear band width VB reaches 0.3 - 0.5mm during rough machining and 0.1 - 0.3mm during fine machining, it means that the cutting performance of the blade has been greatly reduced and needs to be dealt with in time; for high-speed steel blades, due to their relatively weak wear resistance, measures are usually required when the wear band width reaches 0.2 - 0.4mm. However, the specific value needs to be comprehensively judged in combination with factors such as workpiece material, processing requirements, and cutting parameters. If high-precision aerospace parts are processed, the surface quality and dimensional accuracy are strictly required. Even if the blade wear band width is just close to the lower limit, in order to ensure quality, it may be chosen to replace the blade in advance; in some rough machining occasions where the surface quality requirements are not high, the wear band width slightly exceeds the upper limit. If the blade can still cut normally, the use time can be appropriately extended.
In addition, when the blade is broken or damaged, or abnormal vibration and noise are generated during the processing, and it is determined that it is caused by the blade problem after investigation, the blade should be replaced immediately regardless of the wear band width to avoid damage to the workpiece and machine tool, causing greater losses.
(IV) Storage precautions
Proper storage of turning tool blades during non-working hours plays an indispensable role in maintaining their performance and extending their service life, and can ensure that the blades are "full of vitality" in the next processing task.
The storage environment should be kept dry and ventilated, and the humidity should generally be controlled at 40% - 60% to prevent humid air from causing rust and corrosion of the blades. Desiccant can be placed in the storage cabinet to absorb moisture. At the same time, it should be kept away from corrosive substances such as acids and alkalis. Acidic gases, sweat, and cutting fluid residues may corrode the blades. If accidentally contacted, they should be cleaned and handled in time.
When storing, avoid collision and extrusion of blades to prevent damage to the blades. The blades can be classified and placed in special blade boxes, tool holders or drawers, with a certain distance between them to ensure that the blades are independent of each other. For precious carbide and super-hard blades, they should be taken extra care.
For blades that are stored for a long time, it is recommended to apply an appropriate amount of anti-rust oil to form a protective film on the surface of the blade to isolate air and moisture. Before the next use, you need to use a clean cotton cloth to dip in an appropriate amount of cleaning agent, carefully wipe to remove the anti-rust oil, and ensure that the blade is clean before installation and use.
(I) Installation points
The installation of the turning tool blade is the primary link to ensure its normal cutting performance. Accurate installation can effectively improve processing accuracy and efficiency and extend the service life of the blade.
Before installation, be sure to carefully check whether the blade has defects such as chipping and uneven wear. If there is a problem, it should be replaced or repaired in time to avoid affecting subsequent processing. At the same time, the installation surface of the tool bar, tool pad and blade should be wiped spotlessly, and the burrs on the gasket and the orifice should be removed to ensure that the installation position is accurate and correct to avoid blade installation deviation due to dirt and burrs, which will cause changes in cutting angles and reduce processing quality.
During the installation process, the length of the turning tool extending from the tool holder must be strictly controlled. Generally, it should not exceed 2 times the thickness of the tool bar. The extension length of the grooving knife and the cutting knife should also follow the corresponding standards to avoid the weakening of the tool bar rigidity due to excessive extension, vibration under the action of cutting force, and greatly reduce the surface finish of the workpiece. In addition, the tip of the turning tool must be accurately aligned with the center of the workpiece. Too high or too low will cause the turning tool angle to change. The height adjustment of the tip during rough turning and fine turning should be finely operated according to the diameter of the workpiece to ensure stable cutting. The gasket used to install the turning tool should be flat and smooth. Try to use thick gaskets to reduce the number of pieces. Generally, 2-3 pieces are appropriate, and each gasket should be neatly placed directly under the tool bar, with the front end aligned with the edge of the tool holder to prevent the vibration of the turning tool. Finally, when tightening the tool holder screws, use a special wrench to tighten them one by one in rotation to ensure that the screws are evenly stressed and reliably tightened to prevent the blade from loosening and moving during processing.
(II) Wear monitoring
In the process of mechanical processing, it is very important to monitor the wear condition of the turning tool blade in real time. This is like equipping the processing process with an accurate "health doctor" who can detect the "health problems" of the blade in time to ensure smooth processing.
Direct observation of the appearance of the blade is the most basic method. Use the naked eye or a magnifying glass to carefully check whether the blade is worn, chipped, rolled, etc., as well as the width and color changes of the wear band on the back face. For example, a normally worn blade will gradually become less sharp, the wear band on the back face will widen as the cutting time increases, and the color may also change due to cutting heat. Once these signs are found, you need to be alert to the degree of blade wear.
Measuring the dimensional accuracy of the workpiece is as important as the surface roughness. If the dimensional deviation of the processed workpiece exceeds the tolerance range, or the surface roughness value increases significantly, it often means that the blade is severely worn and cannot meet the processing requirements. In the turning of precision shaft parts, as the blade wears, the diameter tolerance of the shaft may expand from ±0.05mm to more than ±0.1mm, and the surface roughness deteriorates from Ra0.8μm to Ra3.2μm. At this time, it is necessary to consider replacing or re-grinding the blade.
Monitoring with the help of advanced instruments and equipment is more accurate and efficient. For example, the use of acoustic emission sensors can keenly capture the tiny elastic waves generated by blade wear and chipping during the cutting process. By analyzing the characteristic parameters of the acoustic emission signal, the blade wear state can be judged; the cutting force dynamometer can monitor the changes in cutting force in real time. When the blade wear increases, the cutting force will increase accordingly. According to the fluctuation of the cutting force, the degree of blade wear can be grasped in time, providing a scientific basis for tool replacement.
(III) Timing of regrinding and replacement
Knowing when to regrind or replace the turning tool blade is a key decision point to maintain processing accuracy and efficiency. Too early or too late may bring adverse consequences.
Generally speaking, when the wear band width of the blade back surface reaches a certain value, regrinding or replacement should be considered. For carbide blades, if the wear band width VB reaches 0.3-0.5mm during rough processing and VB reaches 0.1-0.3mm during fine processing, it means that the cutting performance of the blade has been greatly reduced and needs to be handled in time; high-speed steel blades have relatively weak wear resistance, and measures are usually required when the wear band width reaches 0.2-0.4mm. However, the specific value needs to be comprehensively judged in combination with factors such as workpiece material, processing requirements, and cutting parameters. If high-precision aerospace parts are processed, the surface quality and dimensional accuracy are strictly required. Even if the width of the blade wear band is close to the lower limit, in order to ensure quality, it may be possible to choose to replace the blade in advance; in some rough processing occasions where the surface quality requirements are not high, the wear band width slightly exceeds the upper limit. If the blade can still cut normally, the use time can be appropriately extended.
In addition, when the blade is broken or damaged, or abnormal vibration and noise are generated during processing, and it is determined that it is caused by the blade problem after investigation, the blade should be replaced immediately regardless of the width of the wear band to avoid damage to the workpiece and machine tool, causing greater losses.
(IV) Storage precautions
The proper storage of turning tool blades during non-working hours plays an indispensable role in maintaining their performance and extending their service life, and can ensure that the blade is "full of vitality" in the next processing task.
The storage environment should be kept dry and ventilated, and the humidity should generally be controlled at 40% - 60% to avoid humid air causing rust and corrosion of the blade. Desiccant can be placed in the storage cabinet to absorb moisture. At the same time, stay away from corrosive substances such as acids and alkalis. Acidic gases, sweat, and cutting fluid residues may corrode the blades. If accidentally contacted, they should be cleaned in time.
When storing, avoid collision and extrusion of blades to prevent damage to the blades. Blades can be classified and placed in special blade boxes, tool holders or drawers, with a certain distance between them to ensure that the blades are independent of each other. For precious carbide and super-hard blades, they should be taken extra care.
For blades that are stored for a long time, it is recommended to apply an appropriate amount of anti-rust oil to form a protective film on the surface of the blade to isolate air and moisture. Before the next use, use a clean cotton cloth to dip an appropriate amount of detergent, wipe carefully to remove the anti-rust oil, and ensure that the blade is clean before installation and use.
VI. Summary and Outlook
As the core component in the field of mechanical processing, turning tool blades are rich and diverse in types. Each type has its own unique structure, use, material, shape and parameter characteristics. These factors are intertwined and jointly determine the performance of the blade in different processing scenarios. In practical applications, whether it is turning the outer circle, end face or inner hole, or even thread processing, grooving and cutting operations, accurately selecting the appropriate blade and strictly following the installation, maintenance and maintenance specifications are the key to ensuring processing accuracy, efficiency and extending tool life.
Looking to the future, as the manufacturing industry accelerates towards high-end, intelligent and green development, turning tool blades will also usher in a broader development prospect. On the one hand, the continuous breakthroughs in materials science are expected to give birth to more high-performance and multifunctional new blade materials, further improve cutting performance, and meet the stringent requirements of cutting-edge fields such as aerospace and new energy vehicles for ultra-high precision and ultra-tough tools; on the other hand, the deep integration of digital and intelligent technologies will realize real-time monitoring, intelligent early warning and adaptive adjustment of blade status, greatly improve the automation and intelligence level of the processing process, and reduce labor costs and scrap rates. In addition, the popularization of environmental protection concepts will also make the blade manufacturing process more green and environmentally friendly, and help the sustainable development of the entire mechanical processing industry. In short, turning tool blades will continue to evolve in the wave of technological innovation, and continue to empower and add color to the vigorous development of the global manufacturing 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
