高品质高效率螺纹切削刀具方案

在金属切削加工世界中,我们专注于螺纹成形加工领域。因螺纹加工有苛刻的加工要求,对刀具产品的性能要求提出了极高的要求。我们对螺纹切削刀具的材料牌号（包括基体材料和表面涂层）、刀具的宏观几何结构、刀具刃口的微观结构等方面进行了持续研究与改进,主要研发与生产的螺纹刀具有：高效石油管材管螺纹刀具、高效地质勘探管材螺纹刀具、可转位通用螺纹刀具、高效可转位螺纹铣刀、可换硬质合金刀片丝锥等系列产品。     

新型螺纹切削刀具

<正> 在切削加工中,螺纹切削是最费时间的一种作业。瑞典山德维克·可乐满公司研制的“T—MAXU—lock”螺纹切削刀具是一种快速、安全、准确地进行螺纹加工的新型刀具。这种刀具具有如下特征: ①具有良好的夹紧机构,该刀具用“U—lock”螺钉夹紧,只要将螺钉转动半圆,就可迅速更换切削刃,夹紧稳定可靠,可设计制造公差很严的成形刀片。     

机械工业出版社期刊读者服务部推荐书目

《金属切削刀具设计手册》全书共分16章,介绍了刀具的共同问题:刀具几何参数的定义和刀具材料;普通刀具部分介绍了车刀、孔加工刀具、铣刀和螺纹刀具;复杂刀具部     

旋风铣不锈钢螺纹的刀具磨损及耐用度研究

为了研究旋风铣削不锈钢螺纹的刀具磨损规律,进行了有关切削实验,得出了切削螺纹长度与刀具磨损量的关系曲线,以期改善不锈钢螺纹的加工效率和质量.     

机械工业出版社期刊读者服务部推荐书目

《金属切削刀具设计手册》全书共分16章,介绍了刀具的共同问题:刀具几何参数的定义和刀具材料;普通刀具部分介绍了车刀、孔加工刀具、铣刀和螺纹刀具;复杂刀具部分介绍了拉刀、数控刀具、齿轮刀具和加工非渐开     

数控车削圆弧螺纹程序编制与加工

特殊的圆弧螺纹在普通车床上使用成型刀具加工时,因为受到刀具与工件的接触面积的影响,所以加工出的螺纹精度也不高。为此文中在数控车床上采用小圆弧刀进行切削加工这类圆弧螺纹,可以解决刀具、螺纹牙底的圆弧半径不同影响,加工出精度较高的圆弧螺纹。     

刀具的表面涂层技术

螺纹切削（滚制）刀具表面涂层技术是近20年发展起来的材料表面改性技术。由于我国的紧固件行业获得了空前发展的机遇,对于螺纹加工的要求日趋提高,为此高速、高效、环保已成为紧固件加工的追求目标,如滚制加工硬度不小于40HRC的高强度螺纹,而螺纹切削（滚制）刀具成了提升紧固件技术水平的关键之一。超硬氮化物涂层既可有效延长螺纹切削（滚制）刀具的使用寿命,     

切削用量对铣削非标内螺纹刀具磨损的影响

与传统螺纹加工方法相比,铣削螺纹不仅具有较高的加工精度和加工效率,而且不受螺纹结构的制约,可较为自由地选取合理的加工参数。应用DEFORM-3D软件对铣削非标内螺纹刀具磨损进行仿真,运用正交仿真试验研究切削速度、最大切削厚度和径向切削深度等切削用量对刀具磨损的影响,并对加工参数进行了优化。结果表明:切削刃圆角处刀具磨损最严重,在研究范围内,径向切削深度对刀具磨损的影响最大。     

镍基合金特殊螺纹加工工艺参数优化

针对镍基高温合金材料的难加工性和一种气密封特殊螺纹结构特点,选用硬质合金涂层刀具对Inconel718开展工艺实验研究,利用单因素实验法进行车削试验设计,对加工过程中的粗车、半精车和精车等加工工序的实际情况进行分析研究,提出了镍基高温合金特殊螺纹加工工艺参数的选择原则。通过对切削过程中的刀具磨损和切屑宏观形态进行分析,随着切削速度的提高硬质合金刀具磨损急剧增大,不适宜高速切削。在刀具强度允许的条件下,粗车、半精车时采用低速大进给,切削速度建议控制在40~45 m/min,精车密封面时宜选用高速切削,可达到50 m/min,螺纹加工精度达到了图纸设计技术要求,解决了镍基合金特殊螺纹加工效率低、表面完整性差的难题。     

螺旋角与螺纹升角不一致情况下滚刀前刃面齿距测量分析

在设计螺旋槽滚刀时会出现螺旋角与螺纹升角不一致的情况,此时由于刀具刃口方向螺旋角与刀具左右侧切削刃实际螺纹升角之间有差别,刀具的前刃面与切削刃螺旋平面不垂直,因此在万工显上测量前刃面齿距时需对齿形进行两次投影换算。如仍按螺纹升角与螺旋角一致情况下进行投影换算测量,会引起刀具齿距测量误差。在制造螺旋角与螺纹升角不一致的滚刀时,对滚刀齿距进行正确投影并精确测量。     

基于铣削力精确建模的工件表面让刀误差预测分析

航空航天制造业结构件的高速铣削加工中,在切削力作用下由整体铣削刀具挠度变形所引起的工件表面让刀误差,严重制约零件的加工精度和效率。针对这一问题,通过建立铣削力精确预测模型,结合刀具刚度特点,对工件让刀误差进行预测分析。将切削速度和刀具前角对切削力的影响规律引入二维直角单位切削力预测模型,并通过试验进行相关系数标定。借助等效前角将直角切削力预测系数应用到斜角切削力的预测,通过矢量叠加构建整体刀具三维切削力模型。分析刀具挠度变形对铣削层厚度及铣削接触中心角范围影响规律。基于离散化的刀具模型和切削力模型,建立铣削载荷条件下刀具等效直径悬臂梁模型弯曲变形计算方法。构建以刀具变形对铣削过程影响作用规律为反馈的刚性工件表面让刀误差及切削力柔性预测模型,通过整体铣刀铣削试验验证所建立理论模型的预测精度。     

基于刀具跳动的环形铣刀切削厚度模型的切削力计算

数控铣削过程中,切削变形引起的瞬时切削厚度是影响铣削加工切削力建模的重要参数之一,针对环形铣刀的切削特点,在考虑刀具跳动的情况下,对真实刀刃轨迹运动进行分析。将微细铣削的加工过程用宏观铣削来表示,从而建立了基于宏观铣削过程中刀具跳动下精密加工的瞬时切削厚度。通过仿真模拟和切削力试验来预测切削力,预测结果和试验结果具有一致性,表明该模型可以更好的预测加工过程中的切削力。     

车铣加工切削机理分析

车铣加工通过将车刀更换为铣刀,增加铣刀转动自由度,基于工件转动和铣刀转动的合成运动,完成对工件的加工.车铣加工具有断屑更容易、切削温度低、切削力小等优点,即使工件低速旋转,也能实现高速切削.对车铣加工的切削机理进行了分析,具体包括刀具磨损机理、切屑形成机理、工件表面质量、难加工材料切削等.     

Cutting performance of coated carbide tools in high-speed face milling of AISI H13 hardened steel

In the present study, high-speed face milling of AISI H13 hardened steel was conducted to investigate the cutting performance of coated carbide tools. The characteristics of chip morphology, tool life, tool wear mechanisms, and surface roughness were analyzed and compared for different cutting conditions. It was found that as the cutting speed increased, the chip morphology evolved in different ways under different milling conditions (up, down, and symmetric milling). Individual saw-tooth segments and sphere-like chip formed at the cutting speed of 2,500 m/min. Owing to the relatively low mechanical load, longest tool life can be obtained in up milling when the cutting speed was no more than 1,000 m/min. As the cutting speed increased over 1,500 m/min, highest tool life existed in symmetric milling. When the cutting speed was 500 m/min, owing to the higher mechanical load, the flaked region on the tool rake face in symmetric milling was much larger than that in up and down milling. There was no obvious wear on the tool rake face at the cutting speed of 2,500 m/min due to the short tool-chip contact length. In symmetric milling, the delamination of tool material, which did not occur in up and down milling, was caused by the relatively large cutting force. Abrasion had great effect on the tool flank wear in symmetric milling. With the increment of cutting speed, surface roughness decreased first and then increased rapidly. Lowest surface roughness can be obtained at the cutting speed of about 1,500 m/min.     

Cutting force model considering tool edge geometry for micro end milling process

The analysis of the cutting force in micro end milling plays an important role in characterizing the cutting process, as the tool wear and surface texture depend on the cutting forces. Because the depth of cut is larger than the tool edge radius in conventional cutting, the effect of the tool edge radius can be ignored. However, in micro cutting, this radius has an influence on the cutting mechanism. In this study, an analytical cutting force model for micro end milling is proposed for predicting the cutting forces. The cutting force model, which considers the edge radius of the micro end mill, is simulated. The validity is investigated through the newly developed tool dynamometer for the micro end milling process. The predicted cutting forces were consistent with the experimental results.     

一种螺旋刃球头铣刀的动态铣削力模型

针对高速铣削中广泛应用的螺旋刃球头铣刀建立刀具微元的铣削力模型,给出了瞬时切削厚度的计算方法,通过积分得出了一种新的整体铣削力模型。该模型考虑了动态铣削时刀杆振动对铣削力的影响,实验数据与仿真结果吻合较好,验证了该模型的正确性。     

成形铣齿加工过程中的切削热模型

为了获得铣齿切削时切削区域的温升分布,在分别对铣削热产生和传出的机理,以及刀具和工件之间几何关系分析的基础上,得出包含对应虚拟镜像热源的热源模型。考虑到剪切面热源和刀屑接触面摩擦热源对工件、切屑和刀具的温升作用效果的不同,根据傅里叶导热定律推导出顶刃切削时相应热源的温升计算公式,分别对3者的温升分布进行计算可以获得整个切削区域的温升分布。结果表明,铣削过程中温度随切削的深入而升高,在不改变工件和刀具材料的情况下,进给速度是影响切削温度的主要因素,改变刀盘转速对温升的影响不大。     

Cutting force prediction for ball nose milling of inclined surface

Ball nose milling of complex surfaces is common in the die/mould and aerospace industries. A significant influential factor in complex surface machining by ball nose milling for part accuracy and tool life is the cutting force. There has been little research on cutting force model for ball nose milling on inclined planes. Using such a model ,and by considering the inclination of the tangential plane at the point of contact of the ball nose model, it is possible to predict the cutting force at the particular cutting contact point of the ball nose cutter on a sculptured surface. Hence, this paper presents a cutting force model for ball nose milling on inclined planes for given cutting conditions assuming a fresh or sharp cutter. The development of the cutting force model involves the determination of two associated coefficients: cutting and edge coefficients for a given tool and workpiece combination. A method is proposed for the determination of the coefficients using the inclined plane milling data. The geometry for chip thickness is considered based on inclined surface machining with overlapping of previous pass. The average and maximum cutting forces are considered. These two forces have been observed to be more dominating force-based parameters or features with high correlation with tool wear. The developed cutting force model is verified for various cutting conditions.     

浅谈球头铣刀加工曲面时刀具路径的优化

文章首先分析了球头铣刀的铣削参数和铣削方式,其次,以平行走刀精加工刀具路径为例,从行距、步长、曲面分区加工、切入点和切出点确定、行间和层间附加圆滑转接等方面对刀具路径的优化进行了较详细的说明,文章结论对加工复杂的模具曲面有一定的指导意义.     

考虑左旋切削刃切削连续性的碳纤维增强树脂基复合材料铣削研究

采用右旋切削刃铣刀加工碳纤维增强树脂基复合材料（CFRP）时,纤维层受单向轴向力作用而易产生分层、毛刺等损伤,采用左右旋切削刃共存的多刃微齿铣刀对纤维层施加双向轴向力能有效抑制损伤,但如何保证每层纤维都受到左右旋切削刃的切削作用成为抑制损伤的关键。以多刃微齿铣刀为研究对象,通过设计不同的分屑槽螺旋角,获得左旋切削刃切削面积连续、重叠及未连续三种类型的铣刀。通过实验研究发现：切削面积连续时,CFRP加工表面有少量毛刺及翻边;切削面积重叠时,CFRP加工表面无毛刺及撕裂损伤,效果最好;切削面积未连续时,加工表面有大量毛刺和撕裂损伤;此外,表面粗糙度值会随着分屑槽螺旋角的增大而增大。