In the processing of difficult-to-cut materials represented by heat-resistant alloys such as stainless steel, titanium alloy, and Inconel, a large amount of cutting heat is generated, and high-frequency chattering is likely to occur, making it difficult to achieve efficient and stable processing.
Mitsubishi IMPACT MIRACLE damper end mills' new series of 4-blade ball end mills VF-4SVB, as well as CoolStar with multiple cooling holes, are well received in the field of difficult-to-cut materials processing, and will be introduced separately. Processing cases.
Damping ball end mill VF-4SVB
The R cutting edge of the IMPACT MIRACLE damper ball end mill VF-4SVB adopts an unequal curve shape, which can reduce vibration when machining difficult-to-cut materials and thin-walled parts for aircraft parts. The peripheral edge uses a 45° helix angle and an unequal division shape to improve cutting sharpness and vibration damping. In addition, compared with the conventional four-blade ball end mill, the chip pocket of the bottom edge is large, and the chip discharge performance is improved.
At the same time, with the popularization of 5-axis machining machines, machining methods in which the spindle is tilted at a certain angle to avoid interference with the workpiece are also often employed. The VF-4SVB sets the full length and blade length to the required minimum limit, making it easier to use in size.
The machined surface when processing SUS304 sheet with VF-4SVB. The machining form is a finishing process that simulates components of energy-related products, and the clamping rigidity is very low. The traditional point of view analysis VF-4SVB has more blades than the previous product (3 blades), which should be more prone to chattering, and the actual stable cutting field is larger than the 3-blade. This is an embodiment in which the shape of the unequal curve effectively exerts the effect of suppressing chattering. In the same processing, when the rotation speed is 4800 r/min, the depth of cut is 1 mm, and the cutting width is 2 mm, compared with the conventional product (four-blade), the conventional product (four-blade) has chipping and chipping, and processing cannot be performed. The VF-4SVB has good chip discharge and no damage to the cutting edge, and the processing can be carried out smoothly.
CoolStar Collection
Based on the IMPACT MIRALCE end mill series for machining difficult-to-cut materials, the CoolStar series adds a number of cooling holes to further improve the machining performance of difficult-to-cut materials. The spiral groove of the peripheral edge is provided with a plurality of cooling holes, and the position of the hole is optimized to exert excellent cooling effect and chip discharge. In the past, most of the internal cooling type end mills have cooling holes provided in the bottom edge, and in the processing of the outer peripheral edge, the effect of the internal cooling may not be fully exerted. In contrast, the CoolStar series not only supplies the bottom edge, but also supplies the coolant to the outer peripheral edge, enabling stable processing under various conditions.
Deep groove processing of titanium alloy
When using the 4-blade CoolStar roughing end mill VF-SFPR-CH for deep groove machining of Ti-6Al-4V, the conventional tool has no problem when machining 1D grooves, but when machining deeper grooves, the cutting fluid cannot reach the machining. Position, the chip has a serious bond. In contrast, the VF-SFPR-CH's multiple cooling holes exert their power, and they do not stick during deep groove processing, enabling stable processing.
Cycloidal processing of titanium alloy
The trochoidal machining is very effective in high-efficiency groove processing, but the amount of chip removal per unit time is very large, so it is necessary to discharge the chips steadily.
When using the 6-blade CoolStar right-angle end mill VF-6MHV-CH for the trochoidal machining, the machining conditions such as the cutting depth, the feed rate, the groove width and the tool diameter are more severe. In the past, the tool was bonded, and VF was used. -6MHV-CH can be processed smoothly with its excellent chip discharge and cooling effect.
Here, the characteristics and processing examples of the IMPACT MIRACLE damper ball end mills VF-4SVB and CoolStar series are introduced. VF-4SVB achieves efficient machining of difficult-to-cut materials with its excellent vibration damping (high-frequency chattering resistance) and chip discharge, and the CoolStar series' excellent cooling performance and chip discharge. It is hoped that the above-mentioned end mills will contribute to the processing of difficult-to-cut materials in the Chinese market in the future.
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