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Analysis of cutting problem of shutter mold
The manufacturing process of a shutter mold typically involves 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 step, a consistent and even amount of material is left for the next operation, which helps extend tool life and improve machining efficiency. Different tools are used in each phase, with the roughing stage commonly employing a round insert end mill, a ball nose mill, and an end mill with a large radius. For semi-finishing and finishing, round insert cutters are often preferred due to their versatility and performance.
Round inserts are highly adaptable and can be used on various materials and in multiple directions. When properly applied, they allow for smooth transitions between passes, resulting in a more uniform and reduced machining allowance during the semi-finishing stage. Additionally, the chip thickness of round inserts is variable, allowing for higher feed rates compared to other types of inserts. The cutting action of these blades is smooth, and their design offers strong rigidity, making them suitable for a wide range of cutting operations without limitations.
The effective length of the cut is usually determined by the position of the cutter, as it must withstand the entire cutting force along the cutting edge. During the process, it's crucial to monitor the cutting forces, especially when the tool is positioned at the center of the workpiece. As the cutting edge enters or exits the material, the direction of the radial cutting force changes, which may lead to instability. This can cause vibrations, reducing the quality of the cut and potentially damaging the blade. These issues are common in the machining of shutter molds, and careful attention must be given to avoid any damage to the mold.
In real-world production, it's essential to maintain precision and avoid careless practices that could compromise the mold’s integrity. Always ensure proper tool selection, correct positioning, and consistent monitoring throughout the cutting process.
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