Die & Mould Making - CNC - Computer Numerical Control

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When doing side milling (finishing) with solid carbide, especially in hardened materials, up milling is first choice. It is then easier to get a better tolerance on the straightness of the wall and also a better 90 degree corner. The mismatch between different axial passes will also be less, if none. This is mainly due to the direction of the cutting forces. If having a very sharp cutting edge being in cut the cutting forces tend to ”pull” or ”suck” the cutter towards the material. Up milling can be favourable when having old manual milling machines with large play in the lead screw, because a ”counter pressure” is created which stabilizes the machining. The best way to ensure down milling tool paths in cavity milling is to use contouring type of tool paths. Contouring with the periphery of the milling cutter (for instance a ball nose end mill) often results in a higher productivity, due to more teeth effectively in cut on a larger tool diameter. If the spindle speed is limited in the machine, contouring will help keeping up the cutting speed. This type of tool paths also creates less quick changes in work load and direction. This is of specific importance in HSM applications and hardened materials as the cutting speed and feed are high and the cutting edge and process is more vulnerable to any changes that can create differences in deflection and create vibrations. And ultimately total tool breakdown. Downmilling Bending Upmilling Downmilling Roughing Finishing Roughing - 0.02 mm 0.06 mm Up-milling Finishing 0.00 mm 0.05 mm 27
28 L F L = overhang; d = diameter ; F = radial force E, π = constants; k = all constants etc. put together = l = F x L 3 3 x E x I π x d 4 64 ⇒ = k x F x L3 d 4 64 k = 3 x π x E ⇒ 20 % Overhang reduction reduce tool deflection by 50 % ⇒ 20 % Increased D (Ø10 ⇒ Ø12mm) Reduce Tool Deflection By 50 Solid Carbide Endmills - Finishing/Deflection Relative importance 1 2 3 4 5 6 Parameters 1 Upmilling 2 Low feed/tooth 3 Small radial doc 4 Low number of teeth 5 Material hardness 6 Short outstick Endmills with a higher helix angle have less radial forces and usually run smoother. Endmills with a higher helix angle has more axial forces and the risk of being pulled out from the collet is greater.
Page 1 and 2: APPLICATION GUIDE Die & Mould Makin
Page 3 and 4: 2 INTRODUCTION Within the die and m
Page 5 and 6: 4 When a tool has to be made, for i
Page 7 and 8: 6 CAST-IRON Cast-iron is an ironcar
Page 9 and 10: 8 Hardness of cast iron-is often me
Page 11 and 12: 10 Machinability of cast-iron When
Page 13 and 14: 12 Materiel type Grey Cast-iron All
Page 15 and 16: 14 The next step is to start up the
Page 18 and 19: The die for a cutting tool after ma
Page 20 and 21: This often means that very versatil
Page 22 and 23: If adding, totally, some 50 hours o
Page 24 and 25: THE VERSATILITY OF ROUND INSERT CUT
Page 26 and 27: APPLICATION TECHNOLOGY This is very
Page 30 and 31: Copy milling and plunging operation
Page 32 and 33: For a good tool life it is also mor
Page 34 and 35: PITCH A B A milling cutter, being a
Page 36 and 37: When there is a problem with vibrat
Page 38 and 39: The basic action to take when there
Page 40 and 41: cut. A 32 mm CoroMill 200 cutter wi
Page 42 and 43: The aluminium workpiece in the pict
Page 44 and 45: Vibration severity [mm/s] 4.0 3.0 2
Page 46 and 47: When planning for HSM one should st
Page 48 and 49: MACHINING IN SEGMENTS When machinin
Page 50 and 51: • The remaining stock in the corn
Page 52 and 53: C D a continuous cutting. When taki
Page 54 and 55: There are a lot of questions about
Page 56 and 57: computers and accessories 1,5 years
Page 58 and 59: adii should always be done to creat
Page 60 and 61: ae: 0,1-0,2 mm, fz: 0,02-0,2 mm/z T
Page 62 and 63: Injection moulds and blow moulds ar
Page 64 and 65: Fc [N] 2500 2000 1500 1000 500 0 0
Page 66 and 67: m = 0.015 kg v = 84 m/s n = 40,000
Page 68 and 69: Profile depth Surface with (red lin
Page 70 and 71: CAD geometry principle e.g. NURBS C
Page 72 and 73: Pol1 CAM machine-independent machin
Page 74 and 75: Programmed feedrate F Programmed fe
Page 76 and 77: Cutting fluid in milling Modern cem
Page 78 and 79:
The best way to ensure a perfect ch
Page 80 and 81:
light cutting action is needed smal
Page 82 and 83:
The last parameter to be discussed
Page 84 and 85:
Basically, CVD coating is done thro
Page 86 and 87:
GC4030 is also capable of milling h
Page 88 and 89:
Start values for cutting speed (m/m
Page 90 and 91:
The third operation is machining de
Page 92 and 93:
A 3 mm thick carbide shim supports
Page 94 and 95:
CoroMill 200 Round insert cutters c
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Cutter body The CoroMill 200 has be
Page 98 and 99:
CoroMill 390 CoroMill 390 is a high
Page 100 and 101:
CoroMill 290 Traditionally square s
Page 102 and 103:
BALL NOSE ENDMILL R216 The ball nos
Page 104 and 105:
SOLID CARBIDE ENDMILLS Especially i
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R216.32-N R216.32-N R216.33-N R216.
Page 108 and 109:
DRILLING TOOLS FOR DIES AND MOULDS
Page 110 and 111:
Small hole diameters Regrindable dr
Page 112 and 113:
Deep hole drilling Deep hole drilli
Page 114 and 115:
Connectors are available for both r
Page 116 and 117:
A E F G B C D 115
Page 118 and 119:
It takes less than 20 seconds to ch
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Transmission torque comparison [Nm]
Page 122 and 123:
HSK is a spindle interface and not
Page 124 and 125:
Comparison between holders for clam
Page 126 and 127:
ROUGHING OF CAVITY RECOMMENDED METH
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SEMI-FINISHING RECOMMENDED METHOD C
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ROUGHING COMMON METHOD Roughing of
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ROUGHING COMMON METHOD Roughing of
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SEMI-FINISHING COMMON METHOD Contou
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FINISHING BOTH METHODS Contouring,
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MACHINING EXAMPLE Machining of thin
Page 140 and 141:
MACHINING EXAMPLE Roughing of cavit
Page 142 and 143:
MACHINING EXAMPLE Roughing of press
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MACHINING EXAMPLE Roughing of die f
Page 146 and 147:
MACHINING EXAMPLE Roughing of press
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MACHINING EXAMPLE Semi-finishing of
Page 150 and 151:
MACHINING EXAMPLE Semi-finishing an
Page 152 and 153:
MACHINING EXAMPLE Slotmilling of in
Page 154 and 155:
MACHINING EXAMPLE Semi-finishing of
Page 156 and 157:
MACHINING EXAMPLE Slotmilling of di
Page 158 and 159:
MACHINING EXAMPLE Facemilling of pr
Page 160 and 161:
MACHINING EXAMPLE Drilling through
Page 162 and 163:
MACHINING EXAMPLE Drilling of holes
Page 164 and 165:
MACHINING EXAMPLE Deep hole drillin
Page 166 and 167:
TROUBLE SHOOTING Problem: The machi
Page 168 and 169:
TROUBLE SHOOTING - SOLID CARBIDE EN
Page 170 and 171:
THERMAL CRACKS Tool wear Possible c
Page 172 and 173:
CONSTANT K FOR USE IN POWER REQUIRE
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Basic grades 4040 1025 3040 530 SM3
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BASIC GRADES 4030 4040 H13A 690 CB5
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Basic grades 4040 1025 3040 530 SM3
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BASIC GRADES 4040 H13A Feed/tooth (
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SOLID ENDMILLS High speed machining
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MATERIAL CROSS REFERENCE LIST ISO P
Page 186 and 187:
ISO Coromant Material Classifi- Cou
Page 188 and 189:
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Die & Mould Making - CNC - Computer Numerical Control

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