With the rapid development of the 3C electronics industry, 3C electronic products are upgrading in the direction of high integration and high precision. The internal components of their products are getting smaller and smaller, and their precision and electronic integration are getting higher and higher. In product research and development, lighter, thinner and more portable are the goals pursued by designers, which has led to continuous progress in new materials and new processes.
So, on the premise of precision machining, how to meet the increasing processing needs and control production costs? If a worker wants to do his job well, he must first sharpen his tools. Today, the editor recommends the Helitronic Micro grinder from Walter Machine Tools of Germany and the VP-NRT extrusion tap from OSG, which can shorten the tool processing time and extend the service life of the tap.
German Walter Machine Tools
Helitronic Micro
picture
>>>>
Processing difficulties
1. When grinding the R0.4mm ball head to the 90° position of the outer circle, it needs to be connected to the spline contour line
2. The diameter of the tool clearance is 0.4mm and the total length is 3.3mm. The tool vibration is prone to occur during processing.
>>>>
processing method
The Helitronic Micro machine tool is used to grind the tool and the Helicheck Plus measuring machine is used to check the tool grinding accuracy.
picture
>>>>
Processing and optimization suggestions
Tool name: R0.4mm ball nose contour milling cutter
Optimization suggestion: first increase the clearance diameter, and then perform secondary clearance grinding after grinding the ball head part to ensure that the tool has sufficient rigidity during processing. Because the rotation speed of the Helitronic Micro workpiece spindle reaches 3,000 rpm, precise cylindrical and step grinding can be completed, and molding can be achieved in one go.
>>>>
Processing effect
After the customer adopted the optimized solution for tool processing, the phenomenon of tool flicking no longer occurred, and the processing time was shortened by nearly 2 minutes compared with the previous processing time. The customer expressed great satisfaction.
☞Click to request more information
OSG
VP-NRT extrusion tap
>>>>
Processing difficulties
AL6 series aluminum and AL7 series aluminum materials are increasingly used in product casings in China's 3C market. For the processing of these two aluminum materials, small diameter tapping will be a difficult point in processing. Common tap sizes for small diameter processing are M0.8*0.2, M1*0.25, M1.2*0.2, M1.6*0.35, and M2*0.4. However, because the tap diameter is too small, it is easy to break. Since extrusion taps form threads through plastic deformation of materials and do not produce cutting chips, extrusion taps have the characteristics of long tool life and stable processing compared with cutting taps. OSG recommends extrusion processing for small diameter tapping in the 3C industry.
>>>>
Processing case
A client in South China is processing a tablet casing project. The processing material is AL6R01. Each casing needs to be processed with 28 blind holes or through holes of different diameters. The hole depth is 1~2D, and the tolerance must be within 5H. The tap used by the customer before was melted due to insufficient cooling and excessive processing heat. The processed material melts, peels off and sticks to the tool, which can even cause the tap to break.
OSG's technical staff went to the customer's processing site to conduct an investigation. After evaluating the customer's processing conditions, they recommended VP-NRT extrusion taps for hole processing of M1.6 and above. VP-NRT is a powder high-speed steel extrusion tap from OSG. The surface coating is V coating independently developed by OSG. VP-NRT achieves stable tool life in a wide variety of materials such as carbon steel, alloy steel, stainless steel, copper, brass, aluminum, zinc and alloy castings.
Using the VP-NRT extrusion tap, the surface quality and smoothness of the processed threads are better than what Customer A used before. However, due to the melting problem, VP-NRT extrusion taps cannot cope with processing below M1.6. In order to improve the melting resistance of the tool, OSG changed the original V coating of the VP-NRT standard product to OSG's latest DLC coating. Corresponds to hole machining below M1.6. The high surface smoothness and low friction coefficient of DLC coating can exert excellent performance in processing aluminum materials that require solvent resistance and lubricity. After the coating was improved, the melting problem was successfully solved, and the customer was very satisfied with the improved effect of OSG.
