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Analysis of cutting problem of shutter mold
The cutting process for a shutter mold is typically divided into three main stages: roughing, semi-finishing, and finishing. After the semi-finishing stage, residual milling is performed to prepare for the final finishing process. In each phase, a consistent amount of material is left for the next step, which helps extend tool life and ensures better surface quality. Different tools are used in each stage, depending on the required precision and material removal rate.
During the roughing process, tools such as circular insert end mills, ball nose end mills, and end mills with large radii are commonly used. For semi-finishing and finishing, round inserts are often preferred due to their versatility and efficiency. It's crucial to choose the right tool for each operation to maintain stability and accuracy throughout the cutting process.
Round inserts are highly adaptable and can be used on various materials and in multiple directions. They allow for smooth transitions between passes, resulting in a more uniform and reduced machining allowance during semi-finishing. Additionally, the variable chip thickness of round inserts allows for higher feed rates compared to other types of inserts. This makes them ideal for efficient and smooth cutting operations.
The effective cutting length is influenced by the position of the tool, especially the length that the cutting edge must endure. During the cutting process, it's important to monitor the cutting forces. When the tool is centered on the workpiece, the radial cutting force changes as the blade enters or exits the cut, which can cause vibrations. These vibrations may lead to instability and affect the overall quality of the finished product.
Cutting problems in shutter molds are common and require careful attention. Mistakes during the process can damage the mold and increase production costs. Therefore, it's essential to follow proper procedures, pay attention to details, and ensure that every step is carried out accurately and carefully.
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