Miniature mould and miniature milling bring new opportunity

The spare parts of cutting tool milling of 1mm is obtained inferior the precision of micron class. In the meantime, the immanent complexity of miniature spare parts also brings new opportunity for die manufacturer. When making the state with low cost of labor be goinged to by move simply with medium and mixed pattern every time, the die manufacturer of the United States and Europe can change the more advanced technology such as mould of such as miniature and miniature milling to the competitive advantage with maintaining them. One of machines 　 to machine a mould for small-sized spare parts main challenges of small-sized component are the treatment of miniature spare parts. The production of the direct milling that the mould has effect area and small-sized EDM electrode raises extremely tall requirement to milling craft. The challenge related to miniature milling includes a diameter to fall for 100 micron (the use of μ M) or smaller miniature cutting tool runs to arrive at amounting to 150, the very high rotate speed of 000 Rpm. Exterior quality (Ra) needs to achieve 0.

2 micron. And since be mixed to so small part little detail, polishing is not actual, miniature milling requirement is a kind need not the treatment of polishing. With the diameter 0.

The cutting tool of 1mm machines electrode (the photograph is offerred by Cimatron company) while 　 of technology of 　 miniature milling obtains the quality that miniature milling asks and precision to be in, contented socioeconomic restrains a condition, whole production catenary must be optimized and synchronous. CNC machine tool, cutting tool, knife handle, clamping apparatus and the supplier that quality controls device need to offer correct solution with competitive cost. It is the detailed list of a main question that should raise in miniature milling environment below: The 1) cutting tool, cutting tool of small norms of knife handle and ◆ of 　 of main shaft 　 is the person come true of miniature milling. According to the size of workpiece, they but small to 0.

1mm, and may become smaller in the future. In entrust the usability that cutting tool must consider when project of milling of a miniature is mixed cost. ◆ is when using small diameter cutting tool, the main shaft of high rotate speed is crucial. In main shaft 10, use below 000 Rpm 0.

The cutting tool of 1mm diameter, mean cutting rate (Vc) is only 3.

3 M/min, this is too low! ◆ to rotate speed level 20, 000-150, the main shaft of 000, main shaft and heat bilge knife handle union makes complete dynamic balancing, jumpy quantity be together 0 be must. Otherwise, will harm exterior quality and shorten significantly cutting tool life. System of 2) clamping apparatus, clamp and ◆ of workmanship 　 　 fall in most circumstance, the production of miniature milling spare parts should be installed in finish in clip. For example, cause EDM and milling union probably what cannot accept together not coincide and the mark that receive a knife. The consistency that 3) machine tool and ◆ of 　 of workshop ground 　 need not say to the machine tool must be precision can differentiate very much give 4 fraction (dimension sensor) . ◆ miniature milling can use the function of 5 axes milling well. Tilt the ability that cutting tool is far from material makes its can use shorter cutting tool. But, since current precision compares milling of 5 axes linkage,3 axes milling is differred, when employing 5 axes couplet at miniature milling, must norms of machine tool of careful test and verify and real property. Environment of ◆ machine tool must have the temperature that can accuse (it is insufficient that light has software to compensate a likelihood) avoid vibration. If the machine tool does not have correctly segregation, even if outside workshop of course of a heavy-duty lorry, the oscillatory enough that arises possibly is in workpiece apparently leave a mark. ◆ of 　 of 　 of 4) milling technology depends on the geometrical appearance of the spare parts, the special treatment that miniature milling may need to surmount simple scale down is politic. For example, below a lot of circumstances, go against mill (with blame suitable mill) the milling that will be first consideration is politic. With the CAD/CAM solution of the milling of high accuracy miniature that makes at the mould, have the 3-D cutting tool that one a complete set of uses easily. The requirement 　 of CAD/CAM system everybody thinks on intuition milling machine, knife handle and cutting tool are hard the dinky measure that scale down needs to miniature milling and extremely tall precision. At first view rises, software perhaps is easier ground matchs it seems that. After all someone should say, processing is resembled 0.

Such 0001 numbers should resemble processing to software 1.

0 or 10 easy in that way. With the CAD/CAM solution of the milling of high accuracy miniature that makes at the mould, have the 3-D cutting tool that one a complete set of uses easily. But it is more complex than presenting those who be before. Generate and revise have correct precision, smoothness and successional geometrical figure the CAD solution to small-sized component is an entry point merely. The functional sex that applies to miniature milling to to get solution, CAD system must want to adjust carefully and optimize in order to support undermentioned demand: 1.

Read spare parts model with accurate ground reliably. The precision of detailed to maintaining model, the smallest the need that changes multiple data to change is crucial. 2.

When should make cent range or giving lever to found geometrical appearance for slide block, push rod and top, 0 very close.

1-0.

The form of 01 micron tolerancepublic errand is effective. What maintain C1 and C2 to prevent the clearance between cent face is successional, this is indispensible. 3.

Processing norms is very small much model antrum mould, include special sample spare parts and package. CAM system also must undertake optimizing for miniature milling. NC software must handle close public errand and the treatment that exceed high accuracy. And since jockey cannot intervene,prevent cutting tool destroy, NC software must consider the load cutting bits of perforative treatment process accurately. To support miniature milling adequately, CAM software should can: ◆ is used accurately special refined mathematical model, maintain its thereby complex degree. Having a compositive CAD/CAM solution is ideal, because it eliminated any data changeover in processing. ◆ includes high accuracy inside CAD system, inside the CAD ability of buy, offer inside CAM system have appropriate precision and tangent modelling help (for example, model a top of the face, outspread wait) . ◆ support error is small to 0.

The cutting tool method of 1 micron is calculated. Imperceptible feature should be machined on large part when, this has challenge sex especially. The computation of the parameter of miniature milling class when ◆ support considers actual machine tool to restrain. For example, CAM system may ask to use a diameter 0.

The cutting tool of 1mm, 0.

The step pitch of 005mm and greatly 0 of 10 times.

Radius of circular arc of 05mm point of a knife will provide the result that exceeds essence of life. Generated cutting tool way must arrive accurately decimally hind 5. ◆ supports the treatment strategy that optimizes in the light of miniature milling, if be operated with identical NC,will have rough machining, semifinishing machining and precision work. ◆ to reduce handling time while the cutting tool that protects nicety is avoided at attaint, in use basis of whole treatment process actual mental allowance adjusts feed in order to control the knowledge of load of actual cutting tool. Summary: Mould of miniature system, miniature and miniature milling to miniature spare parts mass-produced it is novel and exciting technology. Had what lose sight of almost with naked eye inferior the precision of micron class and point of a knife, this kind burgeoning and the domain of rapid growth posed numerous challenge to die manufacturer and supplier. The CAD/CAM software technology of new material, new cutting tool, special mould coating and innovation must want to be studied and master. Look from good side, miniature system and miniature milling are searching otherness, get more business and the die manufacturer that are in more favorable position than sweated competitor bring new opportunity. The significant development of this domain needs the cooperation between industry, research organization and government. This kind of collaboration been undertakinging in Europe in. The technical collaboration of the European Union considers to act (CRAFT) project assembled institute of Fraunhofer production technology (the banner supplier of machine tool of IPT) and CAD/CAM, CNC, cutting tool, clamping apparatus will develop what make in the light of miniature to lay methodology of generation material, machine tool and software tool and job. Should be tool industry joins North America to develop this burgeoning seductive and profitable fractionize market when. Technology of system of miniature of 　 of small milling brief introduction has become the whole world to grow one of the fastest industry, need makes the industry of dinky tall nice spare parts, for example biology - medical treatment equipment, optical, and microelectronics (include mobile and computer package) wait to have many demand. Its precision is as high as the part that needs small system treatment 5mm or smaller and curved surface quality is amounted to 0.

2mm or smaller, hardness of its spare parts also achieves 45 HRC or taller. Small milling (Micro-milling) it is to machine a kind of small part and tall nice spare parts brand-new processing technique. Small milling uses very small cutting tool (the diameter is less than 0.

1mm) the curved surface precision that can acquire very little curved surface common difference and high quality, current NC software cannot achieve this precision, so manufacturer must face the following and enormous challenge: The spare parts is out of shape, complex rate increases, must process the work of tiny feature with extremely tall precision, and the special cutting tool of use micron class. For example the diameter is 0.

The workpiece of 1mm, to obtain the curved surface that high accuracy asks, achieve above requirement, small milling technology needs to achieve the following support: 100mm or smaller small diameter cutting tool; Appearance scale (L/D) 10 or the high speed cutting tool that is as high as 100; 150000 R/min or more rotate speed of high speed main shaft; 0.

1mm or less treatment common difference; Can revise geometrical system. Small milling is the future of high speed milling, perfectness the company of mould of tiny essence of life will have greater competition ability. CNC Milling CNC Machining