Newly developed products increase productivity during long tool overhangs

In most cases, the focus of improving production efficiency is on the ability to increase the cutting edge. The cutting edge's cutting ability is improved and the production efficiency can be continuously improved. However, due to the different characteristics of different parts, tool overhang has become one of the important factors in the processing, we are paying more and more attention to the performance of the cutting edge cutting vibration. There is a tendency to vibrate when there is a tool overhang, but in most cases, this problem can be avoided by very slight cutting and the tool slowly approaching the workpiece, but the cutting efficiency is sacrificed. If the tool must enter the hole or cavity, a deflection force will occur, which will cause a tendency to vibrate. Sandvik Coromant's newly developed products not only solve this problem, but also greatly increase production efficiency.

Damping tool

After a period of development, the damping tool has been significantly improved. Compared to the technology that Sandvik Coromant first introduced in the 1970s, modern technology is much more advanced. The original product was used to make certain "impossible" operations possible, including the use of approximately 10 times the diameter of the tool overhang, and in some cases longer. Silent Tools damping tools have reached the most advanced level of technology in the field of vibration damping tools . According to extensive application experience and research and development, the products are becoming more and more mature. As a result, Silent Tools addresses some of the processing challenges in the new arena and is a productivity booster. Silent Tools damping tool has been widely used in applications requiring long tool overhangs. Today's technology not only solves the processing problems, but also increases the production efficiency, maintains a small tolerance range and ensures process safety.

In today's machining world, bore turning, boring, cutting and grooving, and milling operations all require longer tool overhangs and are becoming more common, and in some cases, multiple workpieces may be required for the same workpiece. So far, many long overhang applications have low levels of processing performance, and only meet the most basic requirements for parts to be machined, that is, no cutting vibrations occur, and there is no way to talk about production efficiency. Because the tool vibrates, it is easy to lead to reduced machining safety, poor part quality, high noise level, short tool life, and even scrap. Therefore, cutting parameters lower than the cutting edge capability can often be used, which increases the processing cost and the production time is longer.

Milling process

In the milling process, due to the intermittent cutting action, the vibration tends to occur during the machining process. Due to the use of long overhanging tools , more and more milling processes have a tendency to vibrate. Many methods can avoid the tendency to induce vibrations at once, such as using the correct milling cutter and tool path. However, when the tool overhang (the distance between the spindle end shank flange and the cutting edge) exceeds three times the diameter of the shank, additional measures are required if a product that meets the existing standards is to be machined.

With the increasing demand for tool diameters that are four times or more the tool overhang during milling, we are eager to overcome the effects of vibration because vibration limits production efficiency. In particular, since the axial depth of cut and the amount of feed have to be kept low, the metal removal rate has not been as good as it should be. In many cases, long overhanging tools must be used for both milling and bore turning. For example, on multitasking machines , the B-axis spindle usually prevents the tool from approaching the workpiece, so a tool with a long overhang must be used.

In order to overcome the tendency of vibration, we need to use more high-tech means to manufacture the damping shank, which helps to minimize the amplitude better and more accurately. In other words, we can determine the vibration type of a field and the required damping damping setting very accurately. In the latest R&D work, we have combined a large number of professional techniques and experience in the design and application of vibration damping technology to achieve smoother metal cutting at higher processing rates.

It is not possible to completely eliminate the vibration during processing, but it is now completely reduced to a minimum level without any effect on the machining process. The use of advanced simulation methods, equipment and measurement systems, combined with an in-depth understanding of structural dynamics, completely eliminates the adverse effects of forces on the tool . This research and development work not only achieves the damping function, but also more accurately finds the function of the specific tool overhang.

For the milling process, the new standard adapter does not affect the machining performance due to tool overhang. The standard shank minimizes the typical amplitude of two different overhang ranges. There are currently two different lengths of damping shanks, which are dedicated to milling operations with overhangs of 4 to 5 times the diameter of the shank and 6 to 7 times the diameter of the shank. Customizing the damping adapter allows the milling rod to extend longer. (The tool overhang referred to herein refers to the distance between the spindle end flange and the cutting edge.) These adapters are suitable for the most common areas of longer tool overhang in milling operations. The new system can increase production efficiency and greatly reduce the return on investment of the adapter.

This milling adapter allows for increased axial depth of cut and feed. This greatly increases the potential for productivity and offers high-efficiency milling possibilities for part features such as pockets that exceed the machining range, for example when using face milling cutters with a larger diameter than the toolholder. The potential of new products can extend tool overhangs or increase tool overhang while increasing productivity.

Inner hole turning

Inner hole turning will involve a wider range of tool overhangs. Many parts have deep holes and strict requirements for the overhang of the mast. The overhang range is 4 times - 14 times the diameter of the mast. The correct selection and application of the tool plays a decisive role in the result of the operation, since the hole turning is very sensitive to vibration. One advantage of the Silent Tools damper mast is that the damper mechanism is placed as close as possible to the cutting edge. This mounting method responds quickly to any vibrational tendency.

Ordinary steel masts are ideal for overhanging four times the diameter. The solid carbide mast is suitable for six times diameter applications. For areas with longer overhangs, borehole turning requires the use of a damping mast. The steel damping boring bar is used to machine a hole with a diameter of 10 times, and the reinforced hard alloy damping boring bar is used for a 14-fold diameter overhang. Usually grooving and thread cutting use a lower overhang. In addition, the vibration characteristics of the mechanism of all machine tools are different, that is, the same cutting process vibrates at different frequency points due to the different characteristics of the machine tool . Therefore, it is important to develop a vibration-damping standard tool that can operate normally in as large a frequency range as possible.

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