In modern manufacturing, Engraving and Milling Machining Center is one of the important equipment for high-precision processing. The choice of tool has a vital impact on the processing effect and production efficiency, especially when the processing materials are different, choosing the right tool is particularly critical. The right tool can not only improve the processing accuracy, but also extend the tool life, improve production efficiency, and reduce the failure rate during processing. Next, we will discuss in detail how to choose the right tool according to different processing materials.
1. Understand the characteristics of processing materials
Different materials have different physical and chemical properties during processing, so when selecting tools, factors such as material hardness, strength, toughness, thermal conductivity, corrosion resistance, and surface roughness need to be considered. The following are the characteristics of several common materials:
Metal materials: such as aluminum, steel, titanium alloy, stainless steel, etc., usually require higher cutting force and thermal stability.
Plastics and composite materials: have lower hardness and better machinability, but are prone to cutting heat accumulation.
Wood and soft materials: These materials are relatively soft and may generate greater cutting forces when cutting, so when selecting tools, attention should be paid to cutting speed and tool shape.
Ceramics and carbide: These materials are very hard and usually require very wear-resistant tool materials to deal with them.
2. Choose tools according to material hardness
The hardness of the tool is one of the important selection criteria, especially when processing materials with higher hardness, the hardness of the tool should be higher than the hardness of the workpiece material to avoid premature wear of the tool.
Soft metals such as aluminum alloys and copper alloys: For these materials, high-speed steel (HSS) tools or carbide tools can be used. These materials are relatively easy to cut, and the tools do not need to be too hard. Carbide tools can improve production efficiency while ensuring the durability of the tools.
Medium-hardness metals such as steel, stainless steel, and titanium alloys: When processing these materials, coated carbide tools such as titanium nitride (TiN) or aluminum nitride (AlTiN) coatings are usually required to increase the wear resistance and thermal stability of the tools. **CVD (chemical vapor deposition) or PVD (physical vapor deposition)** coatings can effectively extend the service life of the tool and reduce the tool annealing caused by high temperature.
High-hardness metals (such as tool steel, hardened steel, titanium alloy): For these high-hardness materials, you must choose tools with higher hardness and higher wear resistance, such as PCD (polycrystalline diamond) tools or CBN (cubic boron nitride) tools. These tools can remain sharp when processing high-hardness materials, reduce cutting forces, and thus extend the service life of the tool.
3. Select tool shape according to the cutting characteristics of the material
The shape of the tool determines the cutting method and distribution of cutting forces during the cutting process. Different materials have different requirements for tool shape:
Soft metals such as aluminum and copper: Soft metals generally use high helix angle tools, because a larger helix angle can reduce friction during cutting and improve cutting efficiency. The tool rake angle should be appropriately larger to ensure lower cutting forces and less cutting heat.
Stainless steel and titanium alloy: These materials often generate greater cutting heat, and you need to choose right-angle tools or low helix angle tools to reduce the generation of cutting heat. In addition, the cutting edge of the tool usually requires greater wear resistance and stability, so double-edged or multi-edged tools are used to improve cutting stability and reduce vibration.
Plastics and composite materials: When processing these materials, tungsten steel tools or carbide tools are often selected. The shape of the tool is mainly right-angle tools to minimize the cutting force and temperature accumulation during cutting, and avoid deformation or melting of the material.
4. Tool coating selection
The selection of tool coating can significantly improve the wear resistance and heat resistance of the tool. For different processing materials, the appropriate coating can effectively improve the processing efficiency and tool life.
Soft metals such as aluminum and copper alloys: TiN (titanium nitride) coated tools can be selected. This coating can improve the hardness and wear resistance of the tool, while reducing the friction between the tool and the material.
Stainless steel, titanium alloy and other difficult-to-process materials: It is suitable to select AlTiN (aluminum titanium nitride) coated tools. This coating can withstand high temperatures, adapt to the needs of high cutting temperatures and high cutting forces, reduce tool wear, and ensure precision.
High-hardness materials such as carbide and ceramics: **PVD (physical vapor deposition)** coated tools can be selected. This coating has good thermal stability and wear resistance, and is suitable for precision processing of high-hardness materials.
5. Other factors to note
Cutting speed and feed rate: Different materials have different requirements for cutting speed and feed rate. In the processing of soft metals such as aluminum alloys and copper alloys, higher cutting speeds and feed rates can be used, while in the processing of cemented carbide and ceramics, lower cutting speeds and feed rates are usually required to reduce excessive heat accumulation and tool wear.
Use of coolant: When processing high-temperature materials (such as titanium alloys and stainless steel), the use of coolant can effectively reduce the processing temperature, reduce tool wear and material deformation. Reasonable selection of cooling methods can improve processing quality and tool life.