Cutting machining remains the most prominent method of mechanical processing, occupying a significant role in mechanical manufacturing.
With the advancement of manufacturing technology, cutting machining technology underwent substantial progress in the late 20th century, ushering in a new era characterized by the development of high-speed cutting, the creation of new cutting processes and methodologies, and the supply of comprehensive solutions. technological packages.
High-speed cutting, an advanced and emerging manufacturing technology with higher processing efficiency and quality, is gaining more and more recognition and attention from more and more technicians in industrially developed countries.
Concept and characteristics of high-speed cutting
High-speed machining is a relative concept and lacks a consensual definition. It is generally considered a modern processing technology that uses super-hard material tools to significantly increase cutting speed and feed rate, thereby improving material removal rate, processing accuracy and surface quality. The essence of high-speed machining lies in speed and precision.
Due to the diversity of tool materials, part materials, and processing technologies, it is challenging to provide a definitive definition of the speed range for high-speed cutting. Currently, it is generally considered high-speed machining if the spindle speed is greater than 10,000 m/min or 5 to 10 times the normal cutting speed.
During high-speed machining, not only does the cutting speed increase significantly, but the speed of the machine tool transport components is also much higher than conventional cutting, not only saving cutting time, but also drastically reducing the auxiliary processing time.
Features of high speed cutting include:
1) High processing efficiency.
With the increase in automation, auxiliary time and idle travel time have been greatly reduced, and the effective cutting time accounts for most of the workpiece processing time. Cutting time depends on speed and feed size. Although high-speed cutting has a shallower depth of cut, the high spindle rotational speed and fast feed rate result in a higher metal removal rate per unit time, naturally increasing processing efficiency.
2) High precision processing.
High speed cutting has a high material removal rate and consequently reduces cutting forces. For the same cutting layer parameters, the unit cutting force of high-speed cutting is small, resulting in minimal force deformation of the workpiece during cutting, which helps ensure processing accuracy.
3) High quality of processed surface.
During high-speed cutting, the cutting force is small, amplitude fluctuations are minimal, and the spindle-related excitation frequency is far from the inherent system frequency of the cutting process, so vibrations are not easily generated.
4) Low processing power consumption.
During high-speed cutting, the metal removal rate per unit of power increases significantly. Due to the high removal rate, low energy consumption and short processing time, the energy and equipment utilization rate is improved.
High speed cutting application fields
At present, high-speed machining technology is mainly used in the aerospace industry, automotive industry, mold industry and the processing of complex surfaces and difficult-to-machine materials. High-speed cutting technology is mainly applied in the aerospace industry, where aircraft parts are generally manufactured as a whole with a very high metal removal rate (generally greater than 70%).
In the automotive industry, to meet the personalized demands of the market, production has gradually moved from mass production to diversified batch production.
For mold manufacturing, when high-speed, high-feed and low-cutting depth processing methods are adopted, the processing of hardened steel mold cavities can achieve better surface quality, reducing or even eliminating the need for EDM and grinding , which offers significant results. advantages in reducing preparation time, shortening the process flow and reducing processing time.
