Product Development Technology Corporation (PDT) (Lincoln, Illinois, USA) is a multinational company engaged in the development of new products including tool design and manufacturing. The company has been committed to the exploration and research of advanced processing strategies that reduce cycle times and reduce production costs. Since its inception, PDT has been conducting innovative research on mold processing under high feed conditions using a face-mounted milling cutter with a surface-coated TiAlN coating (using a APKT square stepped blade). Since August 2004, LMT-Fette USA (Cleveland, OH, USA) has developed a high-feeder clip mill (using the new LC280TT insert) under the designation Twincut Vario. It is applied to the process test research of high efficiency mold processing. Next page utility knife,box cutter knife,retractable utility knife,best folding utility knife Yucheng Shuangyan Hardware Plastic Factory , https://www.shuangyanhardware.com
In the final process test study, the Vario milling cutter, which was manufactured and improved several times with the new design, and the patented chip processing technology thus summarized, processed the exhaust manifold shell mold base of a certain type of automobile. . The base dimensions are 914×711×127mm and the workpiece material is 4140 steel (30HRC). The machining was carried out on a Makino MCB 1210 horizontal machining center with a spindle of 50 hp and a spindle No. 50. The in-process knife has an overhang of 178 mm. The results of the processing test are exciting. While ensuring the high precision requirements of the machined parts, significant economic results have been achieved. The machine tool processing cost has dropped from $12 per cubic inch to $6, and the tool cost has dropped from $31 per cubic inch to 2. In the US dollar, the total production cost dropped from US$42 per cubic inch to US$8, and the cost of parts production was 81.6% lower than the original process. Sarullo, PDT's manufacturing engineer, said, "We have reduced the processing time from 17 hours to 5 hours in the process of efficient machining of molds."
Before using the Vario cutter, PDT also used tools from another company. “There was a need to replace 20 blades when machining the car vent shell shell mold base, and the use of the Vario cutter reduced to just 5 blades,†Sarullo told the user about the advantages of the Vario LC280TT blade. “Using the Vario milling cutter saves the company a lot of blades. When milling 500 cubic inches of steel, it can only be processed for 0.5 hours with an expensive blade. The cutting temperature is too high on the cutting head, causing the blade to wear and the accuracy is degraded. Even the damage to the tool body has to stop processing. Now using the Vario milling cutter can extend the tool life to 1 hour and 40 minutes, plus 8 cutting edges per blade, which can greatly reduce the production through indexing. cost."
PDT is also processing a mold base using a 69mm diameter Vario cutter with a cutting speed of 139.3m/min, a spindle speed of 640rpm, a feed rate of 3m/min and a cutting depth of 3mm. . Previously, the conventional milling cutter with a diameter of 50.8 mm produced by the company was only able to be processed with cutting conditions of cutting speed of 122 m/min, spindle speed of 764 rpm, feed rate of 0.78 m/min and depth of cut of 5.08 mm. Comparative experimental studies have shown that the patented cutting edge machining technology and the unique 23? positive rake geometry of the Vario milling cutter reduce the cutting forces acting on the tool tip by 50%, reducing tool wear and reducing cutting temperatures.
The main feature of the high-efficiency chip processing technology is the real high-feed machining. “This is the perfect application for the Vario tool and is the best qualitative leap since the establishment of PDT,†Sarullo said. Therefore, it can reduce the processing time from the past 17 hours to 5 hours when processing the mold cavity.
Structural features of the Vario milling cutter
The Twincut Vario high-feed milling cutter features a unique tool geometry (patented). The tool is designed with two axial and radial misaligned (misaligned) cutting edges for composite machining of the part. According to the processing conditions and the dimensional accuracy requirements of the parts, the two cutting edges of the upper and lower (axial) and left and right (radial) phases of the tool can be efficiently cut according to different plunging angles and adjusted cutting depths, which will form The ratio of width to height is only a quarter of the chip cross section, which greatly reduces the cutting force generated during machining, so that the cutting performance advantage of the tool can be fully utilized.