Being more competitive in machining turned parts and multitasking parts means keeping up with the technological developments of cutting tools and cutting methods. The process that most manufacturers need to perform is usually the cutting of bars, tubes and mechanical parts. Since it is often the first or last step, it is necessary to continue optimization. So how does tool development now address the challenge and how best to solve the cut-off problem?
First, we must establish the best cutting process. When analyzing the cutting process, the first is to classify according to the batch size. When choosing a tool, consider versatility and specificity. For applications where there are multiple or even one variation of a single part, a common tool is often required. In mass production, special tools are required to establish specific processes with the highest cost performance, safety and quality consistency. For medium-volume applications, high productivity and safety with the smallest number of suitable tools is its most important feature.
When looking for the right tool, the cut should be considered as a combination of the three basic factors: the blade overhang required to cut the diameter, the tool width will be affected by the overhang, and the tool width will affect the possible feed of the tool. Rate, while the feed rate determines the time required to complete the process. In addition, the feed rate also determines the insert geometry – the sharp insert geometry is suitable for low feeds, while the robust insert geometry is suitable for high feeds.
Feeding is also related to processing conditions. Processing conditions can be evaluated by stability levels, material conditions, and type of cut to determine if the condition is good, general, or harsh. Workpiece materials can also affect processing conditions as well as blade grade and cutting parameters.
Second, it is necessary to establish the type of tool holder and tooling system that is most suitable for the process. The diameter of the workpiece is critical and the shank is directly related to the required depth of cut. Most cutting depths are in the medium processing range of 6 to 28 mm when cutting, and the depth of cut is 28 to 55 mm for deep cutting and 0.25 to 6 mm for shallow cutting.
When choosing a tool holder, it is necessary to balance versatility and stability. Batch size and operational changes will also affect the selection direction. Since the tool overhang can be set to suit different diameters, the tool that adjusts the blade can be used for a variety of workpiece diameters. On the other hand, the shank with integral reinforced blade is only suitable for a range of diameters, but provides maximum strength.
Furthermore, it is necessary to determine the optimal step for blade selection at the time of cutting. The cutting edge guides the tool during cutting and controls the chip while determining the formation of flash and burrs. The quality of the interface between the relatively thin blade and the shank is fundamental to tool stability. In order to maintain stability, a good track and V-shaped blade holder structure is required and is preferably used in conjunction with a relatively long blade.
The width of the blade varies depending on the cutting depth of the cutting tool. A small cutting depth (workpiece diameter) can be used with a thin blade, while a larger cutting depth requires a wider blade to ensure strength. The number of insert holders on the shank corresponds to the width of the insert. Each system has its own specific blade width range. For example, CoroCut single and double-edged systems have 8 different blade widths ranging from 1.5 to 8 mm, while CoroCut 3 Suitable for shallow cutting, there are 3 blade widths ranging from 1 to 2 mm.
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