Improve the quality of small precision mold processing

Molds include stamping die, plastic die, die-casting die, glass die, casting die, forging die and so on.Good performance, high precision mold can ensure the mass production of the same product, so that its production efficiency is greatly improved, product reliability is improved, and the cost is greatly reduced, so the mold industry is often called "the mother of machinery industry."

In recent years, the world mold industry develops very fast, our country also catch up.The scale, quantity and production level of domestic mould companies and factories are constantly improving.At the same time each mold enterprise each other around product quality, production cycle and price three aspects of fierce competition, in fact, who can in the short production cycle, to provide customers with high quality, high precision, low cost, low price mold, who can win and develop in the competition.For this purpose, enterprises need excellent talents;Advanced CAD/CAM/CAE design and manufacturing technology;Material technology;5 axis NUMERICAL control, high-speed numerical control equipment;It also requires sophisticated final cutting tools - cutting tools.

The time spent in finishing the mold occupies a large proportion in the total machining time.Broadly speaking, die finishing should include fine cutting and grinding. If the efficiency and precision of fine cutting can be improved, not only can the time of fine cutting be shortened, but also the grinding process may be shortened or even unnecessary.So as to improve the competitiveness of the enterprise.

In recent years, the demand for precision stamping die and plastic die, which are mainly based on IT industry, has been increasing rapidly.The components of these molds are precise and complex, for the processing of these parts, the cutting tool requirements for super quality, a variety of shapes.

According to statistics, the processing of this type of precision small mold mainly USES solid carbide small end mills (accounting for 70% of the required tools), and the diameter of these small end mills are mostly under 6mm.

Mitsubishi Integrated Materials, Kobe Cutting Tools has a long history of manufacturing end mills for precision parts and molds.In recent years, MSTAR(Mitsubishi Star) small end milling cutter series has been developed to meet the requirements of more efficient and precise processing of precision small die.

MSTAR series end mills use ultra-fine grain cemented carbide TF15, which Mitsubishi is proud of, on the base material, and MS coating (AlTiN)MSTAR, which is produced by Excellent PVD technology (MIRACLE) of Mitsubishi Kobe Tools co., LTD, has 14 kinds of varieties and 746 kinds of sizes.The 14 varieties include:

Right Angle end milling cutter

2XL(0.2-6mm)4. 2XL6(0.3-2.5mm)5. 4 4mc (1-12mm)6. 4 1 1-12mm)6.

Ball end milling cutter

Ball end mills with 2 edges, short edge and ball head, MS2SB(R0.1-6mm)8. Ball end mills with 2 edges, middle and long edge, ball head, MS2XLB(R0.1-3mm) 9.

Circular end milling cutter

13.2 Arc end milling cutter with long neck and long edge, MS2XLRB(R1-6mm)

Groove end milling cutter

14. 4 edge taper rib trough milling cutter MS4LT(0.2-3mm)

The spiral Angle of end milling cutter is usually 30O, 45o, 60o.The end milling cutter of 30O is suitable for processing carbon steel, alloy steel, cast iron and graphite with hardness of HRC20 or so.45o end milling cutter rear wear, machining surface quality is better than 30o, cutting force is low, suitable for processing HRC40 carbon steel, alloy steel, hard steel, stainless steel, cast iron, aluminum and copper alloy.

The properties of matrix materials and MIRACLE coating are shown in the left table:

MSTAR series main milling cutter manufacturing tolerance:

Manufacturing tolerances for right Angle end milling cutters

D≤3 = -0.005 ~ 0.028; D≤6 = -0.015 ~ -0.038; 8≤D = 0 ~ 0.020

Manufacturing tolerances for ball head main milling cutter

R was ±0.01, D<6 is 0 ~ 0.028, D=6 is 0 ~ -0.038, 8≤D is 0 ~ -0.020

Manufacturing tolerances for circular head main milling cutters

D≤3 ≤D≤6, -0.015 ~ -0.038

Manufacturing tolerances for end mills for groove machining

D<0.5, 0 ~ -0.02 D≥0.5, 0 ~ -0.04.

The bevel tolerance is ±5'.

The higher the manufacturing tolerance, the higher the machining precision, the easier to meet the final machining requirements, which can greatly shorten the mold delivery time and improve the competitiveness of the factory.

Up to now, the surface of the precision molding part is still mainly processed by the integral ball end milling cutter, which is widely used because of its flexibility and adaptability to copying processing and contour processing.In order to process the mold with high precision, the tool requirements are as follows:

(1) Ball head R part precision must be high, and the blade sharp, if R precision is low, according to the program processing mold, it is difficult to ensure the accuracy of size.(2) general ball head center cutting speed is zero, which is not in the cutting, but in the extrusion bite workpiece, resulting in surface quality deterioration, this is the most important tool design improvement.(3) In the finishing, it is impossible to change the tool, so the tool life is long and stable, in order not to produce sudden damage, in addition to the development of the best tool material and coating, but also to design and manufacture the blade shape with high reliability.