Application of Coating in Shaft Machining
Source: China Bearing Network | Time: 2014-02-03
In the ever-evolving landscape of manufacturing, the demands on small-batch and custom part producers are constantly increasing. To stay ahead in a competitive market, high-performance milling techniques have become essential. The focus is not only on meeting technical requirements but also on achieving economic efficiency. Tool and mold manufacturers often compete based on the range of services they can offer—such as the size, data, and precision of parts they can process. Customized strategies can help reduce both time and cost, while also providing valuable insights into process optimization. One major challenge lies in production capacity, which is a critical factor for many machining companies. To optimize costs and remain competitive, toolmaker Paul Horn has developed a series of specialized tools, including the DS full-carbide end mills, DA end mills, spiral cutters, and DM combination cutters. These tools are designed to meet diverse application needs. Users typically select tools based on product manuals or specific standards. This requires a high level of flexibility and quick turnaround times. Horn has built a strong reputation through years of tool development and extensive case studies, allowing them to tackle complex milling challenges effectively. For example, a medical device manufacturer sought to simplify the casting process of a cylindrical support by introducing a funnel-shaped gate. WF Fottner from Tuebingen took on this task, using four templates to create a two-piece spray casting mold. The goal was to produce 2 million parts, with a mold length of 500 mm. A custom mold was designed, along with a tailored process that ensured precision and efficiency. The first step involved roughing out the closed margin template made from hot work die steel (1.2343ESU). A DM series angle cutter with a 12 mm diameter and 2 mm cutting head radius was used, with a 0.2 mm gauge block for inspection. This system uses patented components to connect the shank and blade, offering diameters from 8 to 12 mm. The carbide shank is long and compact, allowing it to reach deep into cavities with high radial accuracy. For additional molds, two brass electrodes were clamped around the intermediate template, enabling efficient processing. Although the milling parameters differ, the DM series cutter can be used independently, simplifying CNC programming. Brass milling cutters in the product catalog come with 2, 3, or 4 flutes and diameters ranging from 0.3 to 12 mm. Recommended roughing parameters include ring and full-radius layouts with 2–4 blades, while semi-finish and finish operations can use double-fluted micro-mills with diameters between 0.3 and 2 mm. The DS series multi-metal full-carbide end mills are ideal for finishing dies with hardness exceeding HRC 55. They feature up to 16 cutting edges and are suitable for materials like brass, graphite, aluminum, plastic, soft and hardened steel, and titanium. With various hard metal coatings, they can handle both "soft-hard" and hard milling processes, reaching HRC 60 and HRC 56–70 respectively. These tools achieve high precision thanks to their four guide rails and cavity support system. After finishing, corrosion processes can enhance surface finishes. The DSMR six-flute end mill with a 6 mm diameter and 1 mm corner radius offers a smooth finish without leaving cutting marks. The spiral head milling cutter enhances power and versatility, proven effective with 1.2343ESU templates and DSK double-blade full-radius cutters. The DA series end mills and spiral cutters are ideal for finishing side spray molds made from 1.2312 material. Their reversible 3-blade layout ensures high stability and precise axial profiles for high-quality parts. Different cutting angles are set according to radial and axial machining processes, matching the template to the operation. Two-blade cutters can achieve 90-degree shoulders with exceptional precision. For deep milling, options like 3 mm or 4.5 mm width are available, with a submerged depth of 1 mm. All DA series brackets and holders are coated with hard materials, enhancing durability. The DS, DA, and DM series offer significant benefits, especially in double-blade machining scenarios. The DSMR series is known for its long service life, while the DM system’s patented connection piece allows for flexible blade and shank combinations. With 0.01 mm tool change accuracy, the DM system improves overall machining precision. The DA system’s high-quality housing and three-blade convertible design boosts the economy of mold ejection processes. Finally, the tool supply process has been simplified through consistent naming, scale, parameters, and machining references, making the entire workflow easier to monitor and program.
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