Zhang Zeyun: Deputy Manager, Tool and Die Branch, Fanghuifeng Electromechanical Co., Ltd.
According to the prediction of experts from the International Production Association, at the end of the 21st century, 50% to 75% of machining (cutting) products will be processed using molds. Therefore, the level of mold production technology is not only an important indicator to measure the level of a country's machinery manufacturing, but also largely determines a country's product quality, efficiency and new product development capabilities. Nowadays, with the rapid update of industrial products, efficient processing has always been the goal pursued in the field of mold manufacturing.
First, the application situation
In the forming and manufacturing of modern molds, the proportion of free-form surfaces is increasing due to the increasing complexity of the mold surface design. Therefore, higher requirements are placed on the mold processing technology, not only to ensure high manufacturing precision and surface quality, but also to pursue The aesthetics of the machined surface also requires high stability and long life of the mold. The traditional molding process hinders the development of the mold in a precise direction. With the deepening of research on high-efficiency processing technology, especially under the continuous development of related technologies such as CAE, CAD, CAM, CAPP software, high-efficiency processing technology has been increasingly applied to the manufacturing and processing of molds, changing the traditional molds. The complex and lengthy process flow of “annealing→milling→heat treatment→electric spark machining→manual grinding→polishing†used in processing reduces the manufacturing cycle of the mold.
As one of the important means of high-efficiency machining, high-speed cutting technology has a high technical content, involving various aspects, including rapid and efficient CNC machining programming, multi-axis simultaneous machining of space free-form surfaces, cutting of difficult-to-machine materials, and numerical control technology. The standardization and standardization of programming have reduced the workload of EDM and manual repair, and ensured the high consistency of mold manufacturing, ensuring mold accuracy, reducing the number of trials, shortening the manufacturing cycle, and changing the past. Relying on the fitter" to correct the thinking mode of the assembly, moving toward the direction of "only equipped with less" or "only equipped with no fit", thereby improving production efficiency and achieving efficient processing.
Second, the requirements of the tool
After studying various related data such as average tool cost and production cost in developed countries, it can be seen that increasing the tool life by 50% can reduce the production cost by 1%, while increasing the processing efficiency by 20% can reduce the production cost by 15%. This fully demonstrates that using modern cutting technology, selecting high-speed, high-efficiency tools, giving full play to the performance and efficiency of machine tools, and achieving high-speed, high-efficiency cutting is the right way to improve efficiency and reduce production costs.
With the development of machine tool technology, the maximum speed of the machine tool spindle is also greatly improved, and the advancement of tool rigidity and dynamic balance performance has laid a good foundation for high-speed cutting of the tool. In order to avoid the centrifugal force generated by the tool imbalance at high speed, it will adversely affect the cutting process of the tool, resulting in a decrease in tool life, workpiece surface quality and shape accuracy. Also consider the connection surface of the spindle and the shank, the interface part and the longer length. Particularly important for the arbor is the radial yaw accuracy and the cantilever length. In order to meet the requirements of the radial oscillating precision of the cylindrical shank during finishing, the connection method of the hydraulic chuck, the shrinking chuck and the force compression chuck should be selected, and the radial oscillating precision can reach 0.001~0.003mm.
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