外文翻譯---高速切削加工在模具制造中的新應(yīng)用

1、<p><b>　　翻譯部分</b></p><p><b>　　英文原文</b></p><p>　　High-speed cutting processing in mold manufacture application</p><p>　　A.J.G. Nuttall *, G. Lodewijks<

2、;/p><p>　　Abstract The current mold application is widespread, also had the very big development with it related die making technology. At present, used the high-speed cutting production mold already to become

3、 the die making the general trend. In some mold Manufacturer, the high speed engine bed big area substitution electrical discharge machine, the high-speed cutting production mold already gradually became the die making t

4、he general trend. It can improve mold's size, the shape and the surface roughnes</p><p>　　Keywords High-speed cutting Grinding tool Grinding tool processing Process technology</p><p>　　1

5、 Introduction</p><p>　　1.1 Introduction</p><p>　　Along with the advance in technology and the industry swift development, the mold already became in the industrial production to use the extreme

6、ly widespread main craft to equip now. The mold takes the important craft equipment, in Industry sectors and so on consumable, electric appliance electron, automobile, airplane manufacture holds the pivotal status. The m

7、anufactured products components rough machining 75%, the precision work 50% and the plastic parts 90% will complete by the mold. At pres</p><p>　　1.2 High-speed cutting process technology</p><p>

8、;　　As the name suggests, the high-speed cutting, first is the high speed, namely must have the high spindle speed, for instance 12000r/min, 18000r/min, 30000r/min, 40000r/min, even also had a higher rotational speed stil

9、l in the experiment; On the other hand, should also have the bigger to feed quantity, like 30000mm/min, 40000mm/min, even 60000mm/min; Has is after again the rapid traverse, trades fast the knife, the main axle trade the

10、 knife, from the static state arrives its needs rotational spee</p><p>　　Next is must aim at the different processing object, the different degree of hardness, the different material quality, the different s

11、hape to choose the corresponding reasonable parameter, but cannot pursue constantly to be high speed and be high speed, regarding the die space processing, the shape is specially complex, but the cutting tool diameter is

12、 also small time, because cutting tool's path is not the simple translation, but is the curve, even has right angle corner time, technological par</p><p>　　The high-speed cutting (HSC) is an advanced tec

13、hnique of manufacture which for the past ten years rapidly rises. Because the high-speed cutting technology has the cutting efficiency to be high, the processing quality high, can process the hard steel stock and the goo

14、d efficiency directly, causes profession and so on aviation, mold, automobile, light industry and information production efficiencies and the manufacture quality obviously enhances, and causes the processing craft and th

15、e equipment c</p><p>　　The high-speed cutting processing is faces for the 21st century a high technology and new technology, it is one kind is different with the traditional processing processing way. Compar

16、es with it, the high-speed cutting processing main axle rotational speed high, cuts high for the speed, the cutting quantity is small, but in the unit time material excises the quantity to increase 3 ~ 6 times actually.

17、It take the high efficiency, the high accuracy and the high surface quality as the basic charact</p><p>　　When with traditional way processing mold, often uses the electric spark machining, but the electrode

18、 design and makes itself is the technological process which time-consuming takes the trouble. But after uses the high-speed cutting processing, because the narrow and small region processing realization and the high grad

19、e superficial result, let the electrode the utilization ratio reduce greatly. Moreover, makes the electrode with the high speed mill also to be possible to make the production eff</p><p>　　The major part mol

20、d may use the high-speed cutting technology to process, like the forging die, the compression casting mold, cast with the blow molding mold and so on. Hammers the cavity body shallowly, the cutting tool life is long; Com

21、pression casting mold size moderate, the productivity is high; Casts with the blow molding mold general size small, quite is economical.</p><p>　　2 the high-speed cutting processing mold relative tradition

22、processes the mold the superiority </p><p>　　2.1 Enhances the productivity </p><p>　　In the high-speed cutting the main axle rotational speed and enters for the speed enhancement, may enhance ma

23、terial removing rate. At the same time, thehigh-speed cutting may process the hard components, a many Cmmponents attipe clamps may complete thick, half essence and the precision work and so on the complete working proced

24、ure, also may meet the components surface quality requirements directly to the complex profile processing, therefore, the high-speed cutting craft often may save the elect</p><p>　　The high-speed cutting pro

25、cessing permission use big to feed rate, enhances 5~10 times compared to the convention machining, the unit interval/unit time material excision rate may enhance 3~6 times, the process period may reduce greatly. This may

26、 use in processing needs to excise the metal massively the components, specially has the very vital significance regarding the aviation industry.</p><p>　　2.2 Improvement processing precishon and surface qua

27、lhty </p><p>　　The high rpeed engine bed must have high performance and so on rigidity and high accuracy, at the same time because cutting force low, the work piece thermal deformation reduces, the cutting t

28、ool distorts slightly, the high-speed cutting processing precision Is very high. Depth of cut small, but enters for the speed quickly, the processing surface roughness is very small, cuts when the aluminum alloy may reac

29、h Ra0.4 ~ 0.6, when cutting steel stock may reach Ra0.2 ~ 0.4.</p><p>　　Compares with the conventional cutting, when high-speed cutting processing the cutting force may reduce 30% at least, this may reduce t

30、he processing regarding the processing rigidity bad components to distort, causes some thin wall class fine work piece the machining into possible. Because revolves high speed time the cutting tool cuts the excitation fr

31、equency is far away from the craft system's forced oscillation, has guaranteed the good processing condition. Because the cutting force is too sm</p><p>　　2.3 The reduced cutting produces quantity of hea

32、t </p><p>　　Because the high-speed cutting processing is the shallow cutting, simultaneously the feed rate is very quick, the knife edge and the work piece contact length and the contact duration were short,

33、 reduced the knife edge and the work piece heat conduction, has avoided when the traditional processing met everywhere in the cutting tool and the work piece to have the big calorimetry shortcoming, guaranteed that the c

34、utting tool worked under the temperature not high condition, lengthened cutting tool'</p><p>　　Fig.1 high speed processing and traditional processing heat conduction </p><p>　　The high-speed

35、 cutting processing process is extremely rapid, 95% above cutting quantity of heat are extremely few, components not because the temperature rise will cause the warp or the inflation distortion. The high-speed cutting is

36、 suitable specially for the processing easy thermal deformation components. Is low regarding the processing melting point the metal which, easy to oxidize (for example magnesium), the high-speed cutting has certain signi

37、ficance.</p><p>　　2.4 advantageoued in the processing thin wall components </p><p>　　Time high-speed cutting's cutting force is small, has the high stability, but the high quality processes

38、the thin wall components. Uses as shown in Figure 2 the lamination down milling the processing method, but high-speed cutting wall thickness 0.2mm, wall high 20mm thin wall components. This time, the knife edge and the w

39、ork piece contact duration was short, has avoided the sidewall distortion.</p><p>　　Figure.2 high-speed cutting thin wall components</p><p>　　2.5 change the part substitutes certain crafts, like

40、 electric spark machining, abrasive machining and so on</p><p>　　High strength and the high degree of hardness's processing is also a high-speed cutting major characteristic, at present, the high-speed c

41、utting has been possible the work hardness to reach HRC60 the components, therefore, the high-speed cutting can process after the heat treatment hardens the work piece. In the tradition processes in mold's craft, bef

42、ore the precision work, hardens the work piece after the heat treatment to carry on the electric spark machining, may omit in the die making craft</p><p>　　the mold's size, the shape and the surface roug

43、hness are very important, if after processing the mold cannot meet the requirements the quality precision, needs the massive handworks to rub repairs the work, the handwork rubs repairs can obtain the good surface qualit

44、y, but it will affect mold's size and the shape precision. Therefore must omit as far as possible in the mold processing rubs manually repairs, improves the mold quality, reduces the production cost and the manufactu

45、ring cycle.</p><p>　　Figure 3 is the traditional mold processing process: The semifinished materials -> rough machining -> semi-finishing -> heat treatment hardens -> the electric spark machining

46、 -> precision work -> to rub manually repairs. Figure 4 is the high speed mold processing process: Hardened semifinished materials -> rough machining -> semi-finishing -> precision work.</p><p&g

47、t;　　Figure.3 the traditional mold processes process</p><p>　　Figure 4 the high speed mold processes process</p><p>　　in Figure 4, in the high speed mold machining process reduced two technologic

48、al processes, probably reduces the process period 30%~50%. In the traditional processing craft's electric spark machining forms the hardened level easily in the melting processing surface layer, degree of hardness ma

49、y reach 1000Hv, brings the difficulty for the following machining and the abrasive machining. The electric spark machining also easy to cause the surface layer fatigue cracking and cutting tool's breakage.</p>

50、<p>　　2.6 Economic efficiency remarkable enhancement</p><p>　　Synthesis above all sorts of merits, namely: The comprehensive efficiency will improve, the quality enhances, the working procedure simplif

51、ies, the engine bed investment and the cutting tool investment as well as the maintenance cost increase and so on, will use the high-speed cutting craft to cause the synthesis economic efficiency remarkable enhancement.

52、</p><p>　　3 high-speed cutting processing craft essential technology</p><p>　　The high speed engine bed and the high speed cutter are the realization high-speed cutting premise and the basic con

53、dition, has the strict request in the high-speed cutting processing to the high speed engine bed performance and the cutting tool material choice. </p><p>　　In order to realize the high-speed cutting process

54、ing, uses the high flexible high speed numerical control engine bed, the processing center generally, also some use special-purpose high speed mills, drilling machine. At the same time the engine bed has the high speed m

55、ain axle to be systematic and the high rapid advance or progress gives the system, the high main axle rigidity characteristic, the high accuracy localization function and the high accuracy insert makes up the function, s

56、pecially t</p><p>　　The high-speed cutting cutting tool and ordinary processes the cutting tool the material to have is very greatly different. The main use cutting tool material has the hard alloy, the crys

57、tal combination diamond (PCD), the crystal combination cube boron nitride (PCBN) and the ceramics and so on. </p><p>　　The high-speed cutting craft technology also is carries on the high-speed cutting proces

58、sing the key. The cutting method chooses is improper, can make the cutting tool to intensify the attrition, cannot achieve the high speed processing completely the goal. The practice proved, if only then the high speed e

59、ngine bed and the cutting tool but do not have the good craft technology to make the instruction, the expensive high-speed cutting processing equipment cannot fully play the role. The high-spe</p><p>　　a. Cu

60、tting way choise </p><p>　　In the high-speed cutting processing, should select the down milling processing as far as possible, because in down milling time, the cutting tool just cut into the thickness of ch

61、ip which the work piece produces to a big way, afterward reduces gradually. When up milling, the cutting tool just cut into the thickness of chip which the work piece produces to be smallest, afterward the accumulation,

62、increased the cutting tool and the work piece friction like this gradually, has the big calorimetry </p><p>　　Figure.5 the cutting tool cuts into the work piece the process hint</p><p>　　b. Main

63、tains constant metal removing rate </p><p>　　The high-speed cutting processing is shallowly suitable for shallowly to cut the depth, the depth of cut should not surpass 0.2/ 0.2mm (ae/Ap), this is for avoids

64、 the cutting tool the position deviation, guarantees processes the mold the geometry precision. Maintains constant metal removing rate, guaranteed adds on the work piece the cutting load is constant, by obtains following

65、 several good processing effect: (1) may maintain constant cutting load; (2) may maintain the scrap size constant; (3)</p><p>　　c.choice of the Feeds way </p><p>　　Regarding has opens the mouth

66、die space the region, feeds as far as possible from material outside, by real-time analysis material cutting condition. But regarding does not have the die space enclosed area, selects the screw feed method, cuts into th

67、e local region.</p><p>　　d. As far as possible reduced cutting tool's commutation rapidly</p><p>　　Reduces the cutting tool as far as possible the rapidly commutation, because the zigzag pat

68、tern mainly applies in the traditional processing, mainly chooses the return route or the sole way cutting in the high-speed cutting processing. This is because in commutation time the NC engine bed must stop (urgently c

69、hanging down) immediately then the again execution next step of operation. As a result of engine bed acceleration limitation, but is easy to create the time the waste, stops anxiously or wh</p><p>　　For exam

70、ple, in the cutting mold corner processing, the traditional processing method is uses the translation (G1), when the cutting tool cuts to the fillet place, the velocity of movement reduces speed, at the same time when en

71、ters for the commutation the cutting tool movement is not continuously, can have the massive friction and the quantity of heat in the intermittent process, if processes the aluminum alloy or other light metal alloys, pro

72、duces the quantity of heat will damage the work piec</p><p>　　If uses the high-speed cutting processing the method, the use is smaller than the cutting mold corner radius cutting tool, the use high speed eng

73、ine bed high accuracy circular arc inserts makes up the function (G2, G3) processes the mold corner, the high speed engine bed circular arc inserts makes up the movement is the continuous process, cannot have the cutting

74、 tool intermittent motion, thus reduced the cutting tool and the mold contact length and the time, avoids having the massive heat. </p><p>　　e In Z direction cutting continual plane</p><p>　　The

75、 traditional processing die space's method uses the profile milling, this processing way increased the cutting tool to cut into, to cut the work piece the number of times, has affected the work piece surface quality,

76、 has limited the engine bed and the cutting tool formidable function display. In the high-speed cutting processing, often uses the Z direction cutting continual plane. Uses step pitch which is smaller than the convention

77、, thus reduces each tooth cutting elimination quantity, the i</p><p>　　4 High-speed cutting process technology in die making application</p><p>　　The high-speed cutting process technology has a

78、series of characteristics and the production benefit aspect's great potential, already becomes country competition research and so on Germany, US and Japan important areas of technology. Now, US, Germany, Japan, Fran

79、ce, Switzerland, Italy produce the different specification's each kind of commercialization high speed engine bed already entered the market, applies in the airplane, the automobile and the die making.</p><

80、;p>　　Along with the high-speed cutting process technology introduction mold industry, has had the very tremendous influence to the traditional mold processing craft, changed the mold processing technical process. Beca

81、use the mold profile is the very complex free surface generally, and degree of hardness is very high, uses conventional the machining method to satisfy the precision and the shape request with difficulty. The conventiona

82、l processing method is after the annealing carries on the milling pr</p><p>　　The high speed milling processing has the highly effective high accuracy in the die making as well as may process the high hard m

83、aterial the merit, already obtained the widespread application in the industrially advanced country. The high-speed cutting process technology introduction mold industry, mainly applies in the following several aspects:&

84、lt;/p><p>　　1) hard mold die space direct processing. After using the high-speed cutting to be possible to process the hard material the characteristic direct processing hard mold die space, improved the qualit

85、y which and the efficiency the mold processes, may substitute for the electric spark machining. </p><p>　　(2) EDM (electric spark) electrode processing. Applied the high-speed cutting technology processing e

86、lectrode to raise the electric spark machining efficiency to play the very major role. The high-speed cutting electrode improved electrode's surface quality and the precision, reduced the following working process.&l

87、t;/p><p>　　(3) fast sample workpiece manufacture. Uses the high-speed cutting processing efficiency high characteristic, may use in processing the plastic and the aluminum alloy model. After the CAD design prod

88、uces the 3D full-scale mockup fast, is higher than the fast prototype manufacture efficiency, the quality is good. </p><p>　　(4) mold's fast repair. The mold often needs to repair in the use process, len

89、gthens the service life, in the past was mainly completes depending on the electrical finishing, now uses the high speed processing to be possible to complete this work quickly, moreover might use the original NC procedu

90、re, did not need to establish.</p><p>　　5 Conclusion</p><p>　　The high-speed cutting processing uses the high cutting velocity and the feed rate, the small radial direction and the axial depth o

91、f cut, the cutting force is small, the processing surface roughness is very small, cutting tool life enhancement; With the high-speed cutting processing way substitution tradition processing way processing mold, might om

92、it the electric spark machining and rub manually repairs, raised the productivity which the mold processed, reduced the production cost, reduced the</p><p>　　The high-speed cutting process technology is the

93、advanced technique of manufacture, has the broad application prospect. Replaces EDM with the high-speed cutting processing (or majority of replaces) speeds up the mold development speed, realizes the craft update major s

94、tep. The promoted application high-speed cutting process technology applies in the mold manufacturing industry, not only may enhance the machine-finishing large scale the efficiency, the quality, reduces the cost, moreov

95、er may lead</p><p>　　References</p><p>　　[1] A.C. Low, J.W. Kyle, Grinding tool technology recent development, The Mechanical Engineers Association, London, 1986. High-speed cutting and grindin

96、g tool manufacture</p><p>　　[2] K.L. Johnson, High-speed cutting and grinding tool manufacture, Cambridge University Press, Cambridge, 1985.</p><p>　　[3] W.DMay, E.L. Morris, D. Atack, new using

97、 of Cutting technology, Applied Physics 30 (1959) 1713–1724.</p><p>　　[4] S.C. Hunter, Grinding tool manufacture, Applied Mechanics 28 (1961) 611–617.</p><p>　　[5] G. Lodewijks, Dynamics of Belt