Basic Classification of Cutting Tools
By End Geometry:
1) Flat-bottomed end mills
2) Flat-bottomed round-angle end mills
3) Ball end mills
4) Indexable insert end mills
02 Basic Geometric Structure of Cutting Tools
03 Geometric Accuracy of Cutting Tools
For finishing operations, cutting tools must have excellent profile accuracy at the cutting edge.
Several possible profile deviations of tools:
1) Accurate profile;
2) Irregular chipping at the cutting edge due to insufficient grinding precision;
3) Radial deviation due to insufficient grinding precision.
If very high workpiece accuracy is required, tools with standard certification should be purchased from the tool manufacturer.
04 Ensuring Minimum Radial Runout Error of the Tool
To ensure accurate spindle operation while ensuring the maximum overhang length of the tool holder and tool system does not exceed the specified value, the radial runout error of the tool must be checked at both the tool holder and the cutting edge. Excessive radial runout error will lead to severe spindle vibration.
05 How to Select the Right Cutting Tool
1) Analyze specific machining conditions, such as spindle and machine tool performance, tool clamping system, lubrication method, etc.;
2) Analyze workpiece material properties;
3) Analyze surface quality, machining accuracy requirements, cost, etc.;
4) Comprehensively consider various factors to make the optimal choice.
06 Calculation Methods for High-Speed Cutting Machining Parameters
Three Important Formulas:
07 Several Important Terms and Machining Parameters in High-Speed Cutting Process
1. Cutting Speed Vc
Definition of Cutting Speed: Vc = N*p*Deff/1000
Vc refers to the appropriate cutting speed value for high-speed machining of a workpiece material under specific tool conditions; it refers to the linear velocity of the tool.
How to Correctly Set the Cutting Speed Vc Value:
Provided by the tool supplier; refer to existing experimental data; establish your own database through extensive cutting experiments.
The Vc value is an important basis for correctly setting other cutting parameters! The effect of cutting speed on surface roughness:
Comparison of chip colors at different cutting speeds:
2. Effective tool diameter Deff
Effective tool diameter and its calculation.
3. Feed per edge fz
Definition of feed per edge:
How to correctly set the feed per edge of the tool:
Provided by the cutting tool supplier; refer to experimental data obtained from other research; obtained through a large number of cutting experiments.
The correct setting of the feed per edge has an extremely important impact on the reasonable distribution of cutting load on the tool.
4. Axial and radial feed ap & ae
Calculation of axial feed:
Depending on the spindle, tool, and material, it will affect the actual results.
The effect of Ae and Fz on surface finish ▼
Calculation methods of various cutting parameters in high-speed machining
08 Setting of machining parameters
(1) Principles for setting machining parameters
1) In high-speed machining, machining parameters must be optimized and cannot be set arbitrarily;
2) The cutting speed Vc value must be set correctly;
3) The feed per edge fz must be set correctly. A reasonable value can maximize the cutting efficiency of the tool, making full use of the tool and improving machining quality and efficiency; it will not affect the tool's service life, thereby saving costs and achieving the goal of truly high-speed machining.
(2) Machining Test: The tool's ability to cut S136 was tested. The tools used in this experiment were as follows:
1) Diameter: 10mm
2) Number of cutting edges: 6
3) Rake angle: -13°
4) Coating: TiAlN
