For composite materials, HSM generally has less cutting force and less power consumption than aluminum alloy processing, according to Crick. Therefore, the machine does not need to increase the machine tool stiffness by increasing the weight of the machine tool to reduce vibration and noise during cutting. It is recommended to select the spindle speed in the range of 10 to 13 000r/min during machining. Of course, it is also possible to select a higher spindle speed. He introduced the user to a processing example in which the domestic OEM chose to machine parts with thicknesses of 0.3 to 0.4 mm at a spindle speed of 24 000 r/min. Previous page Furniture Handle,Minimalist Glass Door Handle,Copper Black Circular Handle,Zinc Alloy Modern Handle Zhaoqing Muyi Hardware Products Co., Ltd , https://www.mywjhandle.com
Starting with the machining of composite materials using machined metal materials, Crick believes that with the increasing strength of composite materials, the use in the aerospace industry is increasing, and machine tools should be designed and manufactured for processing composites. “We can process large composite parts, for example, up to 30m wing skin,†Crick said. “Even as a 9m long 6m body frame can be machined, where the fuselage and other parts of the joint need綷 - Precision machining. Others have slender piles of rafters, poles and beams."
In order to process these thin, long and easy-to-bend parts that Crick describes as “wet noodlesâ€, MAG Cincinnati has developed a dedicated extrusion milling machine for machining aluminum and composite parts using 12 tools with diameters less than 25 mm. The processing range is 4m×2.4m×12m, and the maximum machine tool spindle speed is 24 000r/min.
“With HSM, almost all materials, such as aluminum alloys and composites, can be used to profit from it,†says Haas Automation Reilly. “Even hard steel can take advantage of HSM technology because it can do it. Small back knives, high cutting speeds, high feed rates, ie hard milling under light cutting conditions.†Of course, the new titanium alloy, a more widely used aerospace industry material in the aerospace industry, is also the main material for HSM. one.
“Aluminum alloy processing machines, like a sports car, are used in titanium alloy processing machines, like a bulldozer that walks slowly.†MAG Maintenance company Dan Cooper said, “mainly in the spindle speed, there is a pole. The difference is big. Although HSM's diagnosis is shallow cutting at high speeds, it can also be adapted to the machining of parts for titanium alloys." In particular, HSM also has the cutting advantage that can be used to machine thin-walled parts. Cooper exemplifies that a user can machine thin-walled parts of titanium alloy with a thickness of 0.76 mm and a height of 76 mm. “Such high-wall titanium alloy parts cannot be roughed by conventional machining methods. Because of the large back-feeding process under low-speed and high-torque conditions, it is easy to deform parts and tools, especially for Such as the new titanium alloy 5553 processing is the most typical," Cooper said.
Due to the poor thermal conductivity of the titanium alloy and the high modulus of elasticity combined with its high strength advantages, it becomes difficult to process. Cooper analysis, “although torque and dynamic rigidity have little effect on the processing of aluminum alloys and composite materials, but for The processing properties of titanium alloys are particularly important, so when machining titanium alloys, choose a cutting speed that is much lower than that of aluminum alloys."
Cooper uses two parameters, line speed, cutting speed and feed rate, when analyzing high-speed cutting conditions, instead of the usual spindle speed. The cutting speed is a function of the spindle speed of the machine tool and the tool diameter; the feed rate is a function of the cutting speed and the density of the sipe. This is a problem that must be carefully considered in tool design. The denser the slot (SFM), the greater the feed rate.
MAG Cincinnati uses a newly developed carbide tool to select a feed rate of up to 390 ft/min (118.9 m/min) for machining titanium parts. “When cutting titanium parts at high speeds, we used a 25.4mm diameter, most likely a large sipe density, and chose a 1500r/min spindle speed and a feed rate of 100n/min (2.54m/min),†Cooper said. In addition, the latest machine control system with feedforward function can be used for high-efficiency machining in cutting titanium alloys using the latest machining technology that has been mastered in aluminum alloy machining.
“High-speed machining technology for aluminum alloys is now widely used by users,†said Mazak’s Rudy Canchola. “But the biggest challenge is the high-temperature alloys, for example, the long-term use and use in the aviation industry. Stainless steel 15-5, new titanium alloy 5553 or 6Al4V, etc. These materials were recently used on Mazak VCN-510 C VMC, using a variety of tools for a large number of cutting tests, and finally selected carbide end mills, Cutting at a cutting speed of 500 to 600 ft/min (152.4 to 182.9 m/min) has achieved excellent processing results."
They also selected Seco, Ingersoll, Kennametal and Sandvik tools for the cutting test of stainless steel 15-5 on the Mazak Vortex 815î–¢-II five-axis machining center. The final cutting speed was 400-600 ft/min. (121.9~182.9m/min).
Control systems with feedforward function are not as important for machining superalloys as in aluminum alloy processing because the required cutting speed is not very high in titanium alloy machining. An important feature of this control system is the ability to measure the cutting load acting on each axis and the spindle and adjust it accordingly during cutting. The Mazak machine can obtain signal feedback on the cutting load of each axis and spindle from the servo motor, then change the cutting parameters and even stop the machine or change the tool if necessary.