With the improvement of machine tool stability and the emergence of various new tool materials, it has become possible to process brittle materials with large rake angle tools, so the new file uses a positive 10° rake angle. Compared with the traditional boring tool with a 0° rake angle or a negative rake angle, the rake angle of the positive rake angle produces less cutting force and can effectively reduce the cutting force without reducing the cutting parameters, which not only makes the cutting more brisk, but also It can effectively reduce the occurrence of cutting vibration.
(2) 90° lead angle
Radial cutting component is the main cause of cutting vibration, and the larger the radial component, the more likely it is to cause vibration. The new boring tool uses a 90° lead angle and does not produce a radial cutting component on the main cutting edge. Compared with tools with small angle lead angles, the radial cutting component is greatly reduced, which makes the cutting process more stable.
2. Blade clamping method
The super-hardened blades such as CBN and cermet in the ordinary clamping method cannot make the positive rake angle on the blade, and making the positive rake angle on the tool increases the difficulty of installing and adjusting the blade.
Compared to conventional clamping blades, vertical blades can easily produce blades with large rake angles, and the blades can withstand greater cutting forces and improve tool reliability. The rake face of the vertical insert does not come into contact with other parts or parts of the tool. The design of the chip flute is limited and the optimization is easier. Compared with the conventional clamping method, in most cases, the vertical cutting blade has better chip breaking effect, more reasonable chip space, smoother chip removal, and easier to obtain a stable processing process. Therefore, the new boring blade is clamped in a vertical manner.
3. Blade material and structure
Ceramic knives are a new type of material tool in modern metal cutting. They are characterized by high hardness, high strength, high red hardness, high wear resistance, excellent chemical stability and low friction coefficient. In recent years, with the use of various additives and the application of fine particles, the fracture toughness and impact resistance of ceramic inserts have been greatly improved. At present, there are ceramic types that can be used for roughing under impact load. . The boring process is continuous cutting, and no impact is generated during the cutting process, so a ceramic blade can also be used for rough machining. Compared to CBN tools, ceramic tools have a lower coefficient of friction and produce less cutting forces under the same conditions. Therefore, the new boring tool abandons the CBN insert and selects a ceramic insert that is more conducive to stable cutting.
In order to make the ceramic blade have sufficient strength, after several comparison tests, it is determined that the blade adopts a W-shaped blade with a blade angle of 80°, the blade tip radius is 0.8 mm, and the cutting edge and the cutting edge are passivated. The passivated blade eliminates microscopic defects in the cutting edge, which not only effectively extends the tool life, but also enhances the strength of the cutting edge and improves the stability of the cutting process.
in conclusion
For the characteristics of the new boring tool, we carried out comparative experiments with different processing parameters, and finally determined the processing parameters: cutting speed = 500m / min, feed per tooth = 0.12mm; cutting depth is uncontrollable, unadjusted. As the new boring tool increases the number of cutting edges and the cutting speed, the processing time is reduced to 30.5s, and the machining efficiency is increased by 39%. The anti-vibration measures adopted by the new tool in various aspects improve the stability of the machining process. The abnormal breakage of the blade is eliminated, thereby reducing the number of tool changes and increasing the starting rate of the device. Based on the above two factors, the production efficiency of the OP20 process in which the cylinder bore is rough is increased by about 6%.
From the perspective of the use of the new boring tool, making full use of the good performance of the new tool material, the rational optimization of the tool with the new cutting theory can not only reduce the production cost, but also achieve high-efficiency machining with low power consumption.
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