Correct selection of machine tools
Based on the dynamic characteristics of a machine tool that uses a micro tool for high-speed cutting, the related principles of the above-described high-speed cutting technology are fully achievable. These machines are usually lighter in weight and therefore have a wider range of motion, better sensitivity, flexibility, versatility and high speed. Conventional CNC machines are heavy, so their speed and maneuverability are difficult to achieve at the level of light machine tools, but they can be machined with larger tools. Conventional CNC machines are a bit like SUVs. Although they are powerful, they are not mobile enough or can't be parked in tight spaces. The design and structure of the sports car is not only powerful, but also has a high level of controllability and sensitivity. CNC machines for high-speed cutting of micro tools are very similar to those of sports cars. Just as you can't install a spoiler and paint strips on the SUV, and then expect it to fly like a sports car, you can't replace a high-speed spindle on a bulky conventional CNC machine. High-speed machining with micro tools can be efficiently performed.
When designing a machine, you can choose one of two ideas. You can build a powerful, large machine that can drive large tools for machining with large spindles. Driving large tools requires strong power, which means that large motors with heavier masses must be used. On the other hand, you can also build a lightweight machine for micro tools. Machines designed for high-speed cutting with micro-tools require less cutting force, so the design should focus on speed and sensitivity without the need for large motor drives.
In order to make an airplane complete the flight, which side of the wing is more important, the left wing or the right wing? The answer of course is: To make the plane fly, the wings are equally important and equally indispensable. Similarly, in order to achieve high-speed machining of micro-tools, each of the three elements (micro-tools, cooling methods, and high-speed cutting) is equally important. Without any of them, high efficiency and high reliability are impossible. Sexual and highly flexible processing. Conversely, if the three elements are perfectly combined, you can achieve amazing processing speeds and high levels of processing quality. Its processing advantages are not limited to this, it can completely cancel the subsequent secondary operations such as deburring, degreasing.
Processing example
Here are two examples of high-speed cutting with a micro-tool on a Datron machine: 1 High-speed milling of a 6061-thick aluminum plate with a 1/8" thickness using a 1/4" (6.35mm) single-slot milling cutter with a machining speed of 45000r /min, using alcohol cooling, the machine feed rate is 250ipm; 2 Milling 1/8′′ thick 6061 aluminum plate with small spiral angle double-slot high-speed milling cutter (HSC+) with diameter 1/8′′ (3.175mm), the processing speed is 50000r/min, with alcohol cooling, the machine feed rate is 200ipm.
For high-speed machining, there are some experiences worth noting: 1 should avoid adding bushing on the spindle, because it will increase wear and damage, greatly shorten the life of the spindle; 2 with a smaller step and higher feed rate Machine tool; 3 fast moving tools, using chips to remove heat.
in conclusion
In summary, to get the job done perfectly, you must use the right tools. A golfer will not hit the ball on the grass with a long stick, nor will he use a putter to kick the ball on the tee. Similarly, it is difficult to expect a high-speed spindle to be replaced with a high-speed spindle on a conventional CNC machine. Only machines designed and manufactured for high-speed cutting of micro-tools can meet the demanding requirements of this type of machining.
The advantages of high-speed machining with micro-tools include: low cutting force, not easy to damage the tool, low processing temperature, good surface finish, and can eliminate subsequent deburring, oil removal operation and small tool vibration. The spindle speed of up to 60,000r/min makes the machining speed much faster than in the past, and the machining quality of the workpiece is also improved.
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