The roughing time of large parts is challenging for mold shops. Roughing usually takes a lot of time to cut a large machining allowance, but still leaves the finishing tool to do a lot of work. This leads to a prolonged processing cycle and a drop in production. B&;J Specialty (Wawaka, IN, hereinafter referred to as B&;J) is a mold manufacturer. This problem is also encountered when it requires a tool that can quickly rough the part and leave as much machining allowance as possible for the finished tool.
A cutter-type milling cutter designed for rapid metal removal. Challenge This task involves the roughing of P-20 die steel with hardness HRC36-40. The mold design requires the removal of more than 2000 pounds of material during roughing. In order to complete this heavy-duty roughing task, a lot of time and resources are required. B&J's first machining attempt focused on large mold roughing that took a lot of time, and in some cases it took even a few days to use a standard round-blade face milling cutter. A 4 inch diameter round insert milling cutter was originally used for roughing. Each cutting edge of the insert can only be processed continuously for about 15 minutes. For the hardened P-20 tool steel, the cutting parameters are 0.035" and the feed rate is about 40 ipm. Such cutting performance is far from satisfactory. B&;J's requirements. Its task requires roughing a workpiece that is 30 inches wide, 48 inches long, and 11 inches thick. Further, this roughing tool has a large radius of the tool nose, which means fine The machining tool will eventually encounter more machining. As a result of these concerns, B&J begins to look for tools that can roughen their molds in less time, while still leaving less machining allowance for finishing tools. This can help B&J become more efficient and produce better products for its customers. Solution When it comes to problems with roughing, B&J's Iscar representative provides some advice. The first solution The solution was a four-inch copy milling cutter. Initially this solution produced some amazing results. With the IC908 graded insert, B&J achieved a feed rate of 65 ipm at 450 rpm and a depth of 0.05". When using this milling cutter, the blade life of each cutting edge is at least one hour, four times the original. It has been greatly improved compared to the 15 minute life of each cutting edge of the original tool. Although these advantages have been made, their Iscar representatives believe that the metal removal rate can be further improved. Next, he suggested experimenting with FEEDMILL, a cutter-type milling cutter specifically designed for rapid metal removal (FMR). Combining very little adjustment time, increased tool life and the ability to operate at very high feed rates, FEEDMILL is a great choice for B&J for its roughing tasks.
The FEEDMILL series of tools use a special-shaped triangular insert that can withstand a feed of up to 0.138" per tooth. The triangular insert uses a large arc radius, and the cutting edge profile allows the tool to run at very high feed rates. Each tooth is cut a large amount. In addition, the blade is designed with a boss at the bottom that fits into the matching hole in the insert seat. This allows the insert to withstand higher cutting forces, allowing it to operate at a higher level than conventional Higher feed speed. With this design, the insert is clamped more firmly and thus releases most of the stress normally applied to the clamping screw. The cutting force acts axially on the spindle even when machining Long overhangs also help to provide stability. Deep cavity milling is easier if FEEDMILL is used with the new long overhang BT and DIN69871 shank specifically designed for deep cavity applications in fast feed milling. The shank is designed to improve stability and improve chip evacuation.
This new equipment allows B&J to greatly increase productivity and become more efficient in roughing (roughing the entire mold at higher feed rates, and one blade does not need to be replaced). As a mechanic pointed out, “The feed rate really leaves us a deep impression, especially when you have an overhang of more than eight inches on the main shaft, a 2.5-inch FEEDMILL, and a depth of 0.040 inches. We can rotate at 800. The rpm and feed rate are 250 ipm. "B&;J originally used a 16-mm round blade and left a large arc radius during cutting. Switch to the same size IC908 grade blade, B & J can get a blade life of 45 minutes per blade. “With this performance, we know we have found a solution,†explains engineering manager Jim Reed. In the search for new tools, by using Iscar's FEEDMILL, B&J Specialty can dramatically reduce adjustment time, increase tool life and reduce cycle times.
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