In the processing of non-standard parts in mechanical processing plants, high-speed cutting can not only greatly shorten the processing time, improve the processing efficiency, reduce the processing cost, but also make the surface processing quality and processing accuracy of parts reach a higher level. High-speed machining has the following main characteristics:
(1) Workpiece thermal deformation reduction in high-speed cutting processing, because the chips are cut in a very short time, most of the cutting heat is taken away by the chips, so the workpiece temperature is not high, not only the possibility of thermal deformation is reduced, but also to avoid thermal stress, hot cracks and other surface defects.
(2) It is beneficial to ensure the size and shape accuracy of parts in high-speed cutting processing, the unit cutting force is reduced due to the softening of the cutting layer material, thereby reducing the deformation of parts processing, which is particularly beneficial for the processing of thin-walled parts with poor rigidity.
(3) can obtain better machining surface quality High-speed cutting can reduce the depth of the surface hardening layer, reduce the residual stress of the surface layer and the thermal damage of the surface layer microstructure, so as to reduce the possibility of changes in the mechanical, physical and chemical properties of the surface layer material of the parts, ensure the internal quality of the machined surface and ensure the serviceability of the parts.
(4) Process system vibration reduction In ultra-high-speed cutting, because the machine tool spindle speed is very high, the vibration frequency is far away from the natural frequency of the machine tool, so that the process system vibration is reduced and the processing quality is improved.
(5) Significantly improve the material removal rate, the mechanical processing plant can improve the feed speed while improving the cutting speed, thus significantly improving the material removal rate. For example, ultra-high speed milling, when the cutting thickness is kept unchanged, the feed speed can be increased by 5 to 10 times compared with conventional milling, thus achieving a high material removal rate.
High-speed milling has been widely used in the automotive industry, aerospace industry and mold manufacturing, processing aluminum, magnesium and other light metal alloys, steel and cast iron. For example, the automobile engine cylinder block, cylinder head, reducer shell, the overall aluminum alloy thin-wall parts of the aircraft, hardened die steel and nickel-based alloy, titanium alloy and other difficult materials. The strategy to improve the material removal rate has shifted from slow to fast and light, and the machine tool has shifted to high-speed.