Ultra-high-speed machining tools and ultra-precision tool machining technology
Release Date:
2022-01-10
Ultra-high-speed machining is a modern machining technology that uses cutting tools made of superhard materials to significantly increase cutting speed and feed rate, thereby improving material removal rate, machining accuracy, and machining quality.
I. Technical Overview
Ultra-high-speed machining is a modern machining technology that uses superhard material tools to significantly increase cutting speed and feed rate, thereby improving material removal rate, machining accuracy, and machining quality.
The cutting speed range of ultra-high-speed machining varies depending on the workpiece material and cutting method. Currently, it is generally believed that the cutting speed range for various materials in ultra-high-speed cutting is as follows: aluminum alloy exceeds 1600 m/min, cast iron is 1500 m/min, super-heat-resistant nickel alloy reaches 300 m/min, titanium alloy reaches 150-1000 m/min, and fiber-reinforced plastics are 2000-9000 m/min. The cutting speed range for various cutting processes is as follows: turning 700-7000 m/min, milling 300-6000 m/min, drilling 200-1100 m/min, grinding 250 m/s and above, etc.
Ultra-high-speed machining technology mainly includes: research on the mechanism of ultra-high-speed cutting and grinding, ultra-high-speed spindle unit manufacturing technology, ultra-high-speed feed unit manufacturing technology, ultra-high-speed machining tool and grinding wheel manufacturing technology, and online automatic detection and control technology for ultra-high-speed machining.
Ultra-precision machining currently refers to machining technology where the dimensional accuracy of the workpiece is higher than 0.1 μm, the surface roughness Ra is less than 0.025 μm, and the resolution and repeatability of the machine tool positioning accuracy are higher than 0.01 μm. It is also called submicron machining technology and is developing towards nanometer-level machining technology.
Ultra-precision machining technology mainly includes: research on the mechanism of ultra-precision machining, research on equipment manufacturing technology for ultra-precision machining, research on ultra-precision machining tools and sharpening technology, research on ultra-precision measurement technology and error compensation technology, and research on working environment conditions for ultra-precision machining.
II. Current Status and Domestic and International Development Trends
1. Ultra-high-speed Machining
Developed countries started early and have a high level of research on ultra-high-speed machining. The countries in a leading position in this technology mainly include Germany, Japan, the United States, and Italy.
In ultra-high-speed machining technology, superhard material tools are a prerequisite and condition for achieving ultra-high-speed machining, ultra-high-speed cutting and grinding technology is a modern ultra-high-speed machining process method, and high-speed CNC machine tools and machining centers are key equipment for achieving ultra-high-speed machining. Currently, tool materials have developed from carbon steel and alloy tool steel, through high-speed steel, cemented carbide steel, and ceramic materials, to synthetic diamond and polycrystalline diamond (PCD), cubic boron nitride and polycrystalline cubic boron nitride (CBN). Cutting speed has also increased from the previous 12 m/min to over 1200 m/min with the innovation of tool materials. Grinding wheel materials used to be mainly alumina-based and silicon carbide-based. In the 1950s, G.E. Company in the United States first succeeded in the artificial synthesis of diamond, and in the 1960s, it first successfully developed CBN. In the 1990s, the linear velocity of ceramic or resin-bonded CBN grinding wheels and diamond grinding wheels could reach 125 m/s, some could reach 150 m/s, and single-layer electroplated CBN grinding wheels could reach 250 m/s. Therefore, some people believe that with the continuous development of new tool (grinding wheel) materials, the cutting speed will double every ten years, and the emergence of subsonic and even supersonic machining will not be too far away.
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