Challenge: How to use a setup to process complex parts?
Solution: Turn milling and modern milling cutters are used on multi-task machines or 5-axis machining centers.
Many parts that were originally difficult to manufacture and require several different machining processes on different settings and machines can be manufactured with high efficiency using the milling and milling process. When parts are asymmetrical in shape, or due to planes, cavities, and obstacles, etc., the roundness of the part surface cannot reach 360°, this process shows its superiority. In addition to these major advantages, other benefits of turning and milling include improving chip control, reducing cutting forces, increasing the processing capability of demanding workpiece materials, and improving the ability to deal with interrupted cutting. Turning mills have the metal removal rate of turning, and the surface finish can reach the same level even if it is not better than turning. A major advantage is that the workpiece does not need to rotate at high speeds, which is an advantage when machining unbalanced parts. However, to fully exploit the potential of the milling and milling process, the right milling cutter must be applied correctly. There are hidden dangers, but it is easy to avoid. Sandvik Coromant has developed various tools and methods that can properly control process parameters, thereby expanding the application range of turning and milling and achieving new levels of efficiency and quality. R&D work has led to a complete understanding of how various parameters affect performance and results, providing a key to making use of this compelling potential in manufacturing. For roughing operations, special milling tools are not required for turning and milling; however, to optimize the finishing process, special standard wiper indexable inserts should be used. To smooth the slight surface shape deviation, it is necessary to use a straight wiper edge rather than a regular curved edge for general milling. In the turning milling movement, the cutting point moves back and forth along the cutting edge of the generating surface, which means that the curved cutting edge can cause more height variation in the diameter, thereby increasing the fan depth. As for the hidden dangers of turning and milling, the position of the milling cutter relative to the workpiece is critical to the radial shape accuracy, the pressure and safety of the workpiece, and the productivity of the process. The offset of the axis of rotation of the milling cutter with respect to the axis of rotation of the workpiece (ie the y-axis offset) determines the cutting action and the danger of the milling cutter touching the surface at the bottom. This kind of offset has been carefully studied and determined for the impact and degree of various types of milling cutters suitable for turning and milling. In general, the offset should be between half the cutter diameter and zero, and for larger cutter diameters, a number of specific offsets are often required to create shoulders that meet the desired radius. In general, the milling cutter in the offset position does not leave a sufficiently sharp corner in the groove or the shoulder being machined. Therefore, zero offset is only used for the final finishing. Due to the nature of the machining process (milling a circular surface), there is inevitably a tendency for the radial shape to deviate. Most of these deviations can be offset by the wiper blade, but this error tendency should also be taken into account in the positioning of the milling cutter. Planes or sectors are formed on the surface and vary in height and shape depending on the position of the cutter and the relationship between the diameter of the cutter and the diameter of the workpiece. For example, for the same cutter size, the small workpiece diameter gives a notch larger than the large diameter. Similarly, after extensive testing, the recommended range has been determined to provide the right balance for achieving high quality results. For more information, contact your local Sandvik Coromant sales representative.
What is milling? Turning milling has been for decades. It is related to car pull and thread milling. Turn-milling does not use a fixed single-blade tool. Instead, it uses a rotary cutter to machine the rotating part. There are two methods of turning milling: face milling (orthogonal) and peripheral turning (parallel axis). Face milling is the most common method. It mainly uses end milling and face milling to machine the outside of the workpiece. Peripheral turn milling uses side and face milling or long edge milling cutters, mainly for inner machining. The cutting speed is provided by the rotation of the tool, and the feed is performed by the combination of the rotation of the workpiece and the linear feed of the tool. Therefore, it is only suitable for turning when the workpiece can rotate. Typical size components include shafts and housings with exotic design features, crankshafts, turbine blades, extruder screws, landing gear components, and the like. For limited turn milling, four axes are sufficient, but advanced shapes or conical shapes require five axes, while polygons require all five axes to move synchronously. Milling cutters Indexable insert mills for finishing use one wiper insert, while CoroMill 590 uses axially adjustable inserts and can be equipped with all wiper edges for high-speed turning and surface milling finishing. Today's standard cutters are ideal for turning and can be equipped with dedicated wiper blades. Tools that are optimized for various configurations are constantly emerging. They are suitable for turning milling, such as solid carbide end mills (CoroMill Plura) and large circle cutters (CoroMill 300), with indexable end mills CoroMill 390 Milling cutter CoroMill 245 is more common. In addition, plunge cutters are suitable for some slotting applications (CoroMill 210). When is suitable for turning milling
Today's parts are becoming more and more complex, and the manufacturing industry's voice for efficiency is also rising. As a result, the turning and milling process has many uses because it can process exotic shapes and can often complete parts processing in one setup. The evolution of four-axis and five-axis machining centers, coupled with the recent multi-tasking machine tools have made the turning and milling process more feasible.
Summary Milling may be a process that determines whether a part is left on the machine or it must be transferred to another machine. Combining a rotating workpiece with a rotary tool with linear feed offers the possibility of using a standard cutter to machine odd-shaped parts.
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