HIGH SPEED MILLING OF GRAPHITE ELECTRODE WITH ENDMILL OF SMALL DIAMETER

Graphite becomes the prevailing electrode material in electrical discharging machining （EDM）currently.Orthogonal cutting experiments are carried out to study the characteristics of graphite chip formation process.High speed milling experiments are conducted to study tool wear and cutting forces.The results show that depth of cut has great influence on graphite chip formation.The removal process of graphite in high speed milling is the mutual result of cutting and grinding process. Graphite is prone to cause severe abrasion wear to coated carbide endmills due to its high abrasiveness nature.The major patterns of tool wear are flank wear,rake wear,micro-chipping and breakage. Cutting forces can be reduced by adoption of higher cutting speed,moderate feed per tooth,smaller radial and axial depths of cut,and up cutting.

Wear Mechanism of Cemented Carbide Tool in High Speed Milling of Stainless Steel

Adhesion of cutting tool and chip often occurs when machining stainless steels with cemented carbide tools. Wear mechanism of cemented carbide tool in high speed milling of stainless steel 0Cr13Ni4 Mo was studied in this work. Machining tests on high speed milling of 0Cr13Ni4 Mo with a cemented carbide tool are conducted. The cutting force and cutting temperature are measured. The wear pattern is recorded and analyzed by high?speed camera, scanning electron microscope(SEM) and energy dispersive X?ray spectroscopy(EDS). It is found that adhesive wear was the dominant wear pattern causing tool failure. The process and microcosmic mechanism of the tool’s adhesive wear are analyzed and discussed based on the experimental results. It is shown that adhesive wear of the tool occurs due to the wear of coating, the a nity of elements Fe and Co, and the grinding of workpiece materials to the tool material. The process of adhesive wear includes both microcosmic elements di usion and macroscopic cyclic process of adhe?sion, tearing and fracture.

Radial Grip Rigidity of the Matching of Lengthened Shrink-fit Holder and Cutter in High-speed Milling

Though the lengthened shrink-fit holder (LSFH) is widely applied in high speed milling of the parts characterized by deep cavities at present, its design and selection mainly depends on the experience and lacks a correct theoretical guidance. In this paper, attention is focus on the radial grip rigidity of the matching of LSFH and cutter in high speed milling. Based on the experiment modal analysis (EMA) technique, an accurate finite element model of the matching of LSFH and cutter is established firstly. Subsequently, the influence of different interference, grip length and spindle speed on the grip rigidity of LSFH are analyzed. The analysis results show that there is a reasonable interference and grip length between the LSFH and cutter so that to have a steepless grip and have a good radial grip rigidity and at the same time to avoid the strength of LSFH to exceed it’s yield limit which will reduce the precision and service life of LSFH, besides when spindle speed reach a extension the weakening influence of the centrifugal force on the radial grip rigidity of the matching of LSFH and cutter should been taken into account. Finally, the finite element analysis results are verified based on the construction of measurement method of the grip rigidity and the results fit very well. The studies provide a theoretical basis for the design, selection and the serialization and standardization of the matching of LSFH and cutter.

Engagement Angle Modeling for Multiple-circle Continuous Machining and Its Application in the Pocket Machining

The progressive cutting based on auxiliary paths is an effective machining method for the material accumulating region inside the mould pocket. But the method is commonly based on the radial depth of cut as the control parameter, further more there is no more appropriate adjustment and control approach. The end-users often fall to set the parameter correctly, which leads to excessive tool load in the process of actual machining. In order to make more reasonable control of the machining load and toolpath, an engagement angle modeling method for multiplecircle continuous machining is presented. The distribution mode of multiple circles, dynamic changing process of engagement angle, extreme and average value of engage- ment angle are carefully considered. Based on the engagement angle model, numerous application techniques for mould pocket machining are presented, involving the calculation of the milling force in multiple-circle continuous machining, and rough and finish machining path planning and load control for the material accumulating region inside the pocket, and other aspects. Simulation and actual machining experiments show that the engagement angle modeling method for multiple-circle continuous machining is correct and reliable, and the related numerous application techniques for pocket machining are feasible and effective. The proposed research contributes to the analysis and control tool load effectively and tool-path planning reasonably for the material accumulating region inside the mould pocket.