Application of Coating in Shaft Machining
Source: China Bearing Network | Time: 2014-02-03
In modern manufacturing, the increasing complexity of machining tasks has led to higher demands on small-batch and custom part producers. To stay competitive, it's essential to adopt advanced machining techniques such as high-power milling. This not only meets technical and economic requirements but also helps improve productivity and reduce costs. Tool and mold makers often compete based on the range of services they offer—such as the size, data, and precision of the workpieces they can process. Customized strategies that focus on time and cost efficiency, along with expert advice on process optimization, are becoming increasingly important. One of the key challenges in this field is maintaining production power while keeping costs under control. Tool manufacturer Paul Horn has developed a range of specialized tools, including the DS series full-carbide end mills, DA series end mills, spiral cutters, and DM series combination cutters. These products are designed for flexibility, precision, and cost-effectiveness across various applications. Users typically choose tools based on product manuals or specific standards, which requires a wide variety of tooling solutions. Horn has extensive experience in tool development and has analyzed numerous application cases over the years. This deep expertise allows them to tackle complex machining challenges effectively. A medical device company sought to simplify the casting process of a cylindrical support by using a funnel-shaped gate. WF Fottner from Tuebingen took on the challenge, creating a two-piece spray casting mold using four templates. The project required 2 million machining cycles, with a mold margin length of 500 mm. A special mold was designed to meet the user’s needs, ensuring precision and efficiency. The first step involved roughing out the closed margin template made of hot work die steel 1.2343ESU. Using a DM series angle cutter with a 12 mm diameter and a 2 mm cutting head radius, the process was optimized with a 0.2 mm gauge block for inspection. The patented connection between the shank and blade allowed for diameters ranging from 8 to 12 mm, offering flexibility and precision. The carbide shank design, at 140 mm long, enabled access to tight cavities while maintaining high radial accuracy. For additional molds, two brass electrodes were clamped around the intermediate template, allowing for efficient processing. Though their milling parameters differ, the DM series cutters proved versatile, simplifying CNC programming. The DS series multi-metal full-carbide end mills are ideal for finishing dies with hardness beyond HRC 55. With up to 16 cutting edges, they are suitable for a wide range of materials, including brass, graphite, aluminum, plastic, soft and hardened steel, and titanium alloys. The use of different hard metals and coatings enables "soft-hard milling" up to HRC 60 and hard milling up to HRC 56–70. The tool holders achieve H5 precision, with radial accuracy up to 0.005 mm, making them perfect for high-quality finishing. The DSMR six-flute end mill with a 6 mm diameter and 1 mm corner radius ensures a smooth finish without leaving cutting marks. The spiral head milling cutter, combined with the DSK double-knife full-radius cutter, demonstrates the versatility and cost-efficiency of the DS system. The DA series end mills and spiral cutters are used for finishing side spray molds made from 1.2312 material. Available in sizes from 16 to 32 mm, these tools feature a reversible three-blade layout, ensuring stability and high surface quality. Different cutting angles are set according to radial and axial machining processes, allowing precise shoulder cuts at 90 degrees. For deep milling, options include a 3 mm or 4.5 mm width depending on the plate size, with a maximum submerged depth of 1 mm. All components in the DA series are coated with hard materials, enhancing durability and performance. The DS, DA, and DM series milling systems have proven their value in simple double-knife machining scenarios. The DSMR series is known for its long service life, while the DM system uses a patented connecting piece between the shank and cutter, allowing for multiple blade and shank combinations. With 0.01 mm tool change accuracy, the system improves overall machining precision. The DA system features high-quality housing and a three-blade convertible layout, improving the economy of ejector mold processing. 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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