In most cases, the focus of improving production efficiency is on the ability to increase the cutting edge. The cutting edge's cutting ability is improved and the production efficiency can be continuously improved. However, due to the different characteristics of different parts, tool overhang has become one of the important factors in the processing, we are paying more and more attention to the performance of the cutting edge cutting vibration. There is a tendency to vibrate when there is a tool overhang, but in most cases, this problem can be avoided by very slight cutting and the tool slowly approaching the workpiece, but the cutting efficiency is sacrificed. If the tool must enter the hole or cavity, a deflection force will occur, which will cause a tendency to vibrate.
Long overhanging tool
In today's machining world, bore turning, boring, cutting and grooving, and milling operations all require longer tool overhangs and are becoming more common, and in some cases, multiple workpieces may be required for the same workpiece. So far, many long overhang applications have low levels of processing performance, and only meet the most basic requirements for parts to be machined, that is, no cutting vibrations occur, and there is no way to talk about production efficiency. Because the tool vibrates, it is easy to lead to reduced machining safety, poor part quality, high noise level, short tool life, and even scrap. Therefore, cutting parameters lower than the cutting edge capability can often be used, which increases the processing cost and the production time is longer.
In the milling process, due to the intermittent cutting action, the vibration tends to occur during the machining process. Due to the use of long overhanging tools, more and more milling processes have a tendency to vibrate. Many methods can avoid the tendency to induce vibrations at once, such as using the correct milling cutter and tool path. However, when the tool overhang (the distance between the spindle end shank flange and the cutting edge) exceeds three times the diameter of the shank, additional measures are required if a product that meets the existing standards is to be machined.
With the increasing demand for tool diameters that are four times or more the tool overhang during milling, we are eager to overcome the effects of vibration because vibration limits production efficiency. In particular, since the axial depth of cut and the amount of feed have to be kept low, the metal removal rate has not been as good as it should be. In many cases, long overhanging tools must be used for both milling and bore turning. For example, on multitasking machines, the B-axis spindle usually prevents the tool from approaching the workpiece, so a tool with a long overhang must be used.
In order to overcome the tendency of vibration, we need to use more high-tech means to manufacture the damping shank, which helps to minimize the amplitude better and more accurately. In other words, we can determine the vibration type of a field and the required damping damping setting very accurately. In the latest R&D work, we have combined a large number of professional techniques and experience in the design and application of vibration damping technology to achieve smoother metal cutting at higher processing rates.
It is not possible to completely eliminate the vibration during processing, but it is now completely reduced to a minimum level without any effect on the machining process. The use of advanced simulation methods, equipment and measurement systems, combined with an in-depth understanding of structural dynamics, completely eliminates the adverse effects of forces on the tool. This research and development work not only achieves the damping function, but also more accurately finds the function of the specific tool overhang.
For the milling process, the new standard adapter does not affect the machining performance due to tool overhang. The standard shank minimizes the typical amplitude of two different overhang ranges. There are currently two different lengths of damping shanks, which are dedicated to milling operations with overhangs of 4 to 5 times the diameter of the shank and 6 to 7 times the diameter of the shank. Customizing the damping adapter allows the milling rod to extend longer. (The tool overhang referred to herein refers to the distance between the spindle end flange and the cutting edge.) These adapters are suitable for the most common areas of longer tool overhang in milling operations. The new system can increase production efficiency and greatly reduce the return on investment of the adapter.
This milling adapter allows for increased axial depth of cut and feed. This greatly increases the potential for productivity and offers high-efficiency milling possibilities for part features such as pockets that exceed the machining range, for example when using face milling cutters with a larger diameter than the toolholder. The potential of new products can extend tool overhangs or increase tool overhang while increasing productivity.
Inner hole turning
Inner hole turning will involve a wider range of tool overhangs. Many parts have deep holes and strict requirements for the overhang of the mast. The overhang range is 4 times - 14 times the diameter of the mast. The correct selection and application of the tool plays a decisive role in the result of the operation, since the hole turning is very sensitive to vibration. One advantage of the Silent Tools damper mast is that the damper mechanism is placed as close as possible to the cutting edge. This mounting method responds quickly to any vibrational tendency.
Ordinary steel masts are ideal for overhanging four times the diameter. The solid carbide mast is suitable for six times diameter applications. For areas with longer overhangs, borehole turning requires the use of a damping mast. The steel damping boring bar is used to machine a hole with a diameter of 10 times, and the reinforced hard alloy damping boring bar is used for a 14-fold diameter overhang. Usually grooving and thread cutting use a lower overhang. In addition, the vibration characteristics of the mechanism of all machine tools are different, that is, the same cutting process vibrates at different frequency points due to the different characteristics of the machine tool. Therefore, it is important to develop a vibration-damping standard tool that can operate normally in as large a frequency range as possible.
The aperture and mast diameter used vary greatly during the damping measures. The standard tooling system has a machining diameter of 10 to 250 mm, while custom tool products have a larger cover diameter.
There are three reasons for the use of damping masts for bore turning: maintaining small tolerances and excellent surface quality, minimizing machining time with a minimum number of passes, and using competitive and economical processing rates. At this point production efficiency and safety are the most critical, because the processing of many parts is very competitive.
Now, the combination of the mast and the cutting head for internal hole turning benefits from machining. For small diameter machining with a hole diameter of less than 20 mm, both T- and D-type insert types can be used to optimize the ongoing process at hand, for example when the tolerance limits are small and for hard part turning. For applications with a hole diameter of 20 mm or more, an interchangeable cutting head can be used, which is flexible, safe, and easy to clamp.
The use of high pressure cooling technology is very important when turning holes in the bore. By adding a coolant nozzle behind the cutting edge, chip control and discharge can be improved, with the goal of making full use of the coolant equipment on the machine. A shank with a fixed nozzle ensures that the coolant is precisely injected into the cutting area, improving chip breaking performance and discharging the chip off the hole and transferring it to the conveyor. A quick-change shank system is used on the turning center. This system can usually be designed with a high-pressure cooling water supply nozzle. Convenient use of high pressure cooling water to blow iron filings away from the processing area. These units are equipped with built-in fittings and supply lines, and the tool change time is long when an external pipe must be used. An optimized cutting unit with preset fixed nozzles reduces the assembly time of the machine.
The correct method for turning the inner hole can make a big difference in machining performance, safety and machining results. For example, Sandvik Coromant's three-pass method, in which the programming part includes the programmed diameter is larger than the required diameter. When it takes more than 30 minutes to repeatedly process to achieve a small tolerance range, the inner hole turning of Sandvik Coromant can be completed in less than five minutes, and the advantage is particularly obvious. The reason why the processing time can be greatly shortened is to eliminate a lot of unnecessary uncertainty caused by the small depth of the heuristic processing.
Since the cutting edge fails to participate correctly in the cutting, and the measurement process needs to be paused many times, the production efficiency is low and the cutting process is unstable, which will destroy the machining accuracy of the hole. This method minimizes the correct number of cuts and is suitable for over-hole turning with 3 to 4 times diameter, with tool diameters â‰¥ 13 mm, suitable for various material types, with normal or recommended cutting parameter.
The current approach is to solve the vibration problem that has a negative impact on processing, which is quite different from the previous method. Although solving the problem is still part of the application of these tools, our focus is on improving productivity, ensuring process safety and quality consistency.
Improve the overall stability of the system by increasing the rigidity of the system or by increasing the damping capacity of the system by using a damping tool. The most robust and stable tool holder system, such as the ISO-compliant Coromant Capto interface, has no effect on all parts of the System. The natural frequency of the machine tool is another important factor in the "system". To achieve full optimization, consider improving the different structures of a single machine to increase overall stability.
The large mast with Coromant Capto C10 interface can be used for bore turning with a hole diameter of more than 100 mm and a diameter of 10 times, turning high quality holes at high metal removal rates. The quick change function allows quick installation of the mast and high accuracy. The mast is mainly used for flat lathes and heavy duty machining of relatively large holes in large turning centers.
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Label: How to improve long tool production efficiency
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Mol File: 141-52-6.mol
Melting point 260 Â°C
Boiling point 91Â°C
density 0.868 g/mL at 25 Â°C
vapor density 1.6 (vs air)
vapor pressure <0.1 mm Hg ( 20 Â°C)
storage temp. Store at R.T.
solubility Soluble in ethanol and methanol.
PH 13 (5g/l, H2O, 20â„ƒ)
Water Solubility Miscible
Stability: Reacts violently with acids, water. Incompatible with chlorinated solvents, moisture. Absorbs carbon dioxide from the air. Highly flammable.
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