In recent years, the miniaturization of components has become a development trend. Micromechanical products are increasingly being used in many technical fields such as aerospace, automotive, electronics, mobile communications, medical, optical and mechanical manufacturing. The miniaturization of components has placed higher demands on processing technology. The production of these small and high-precision parts and molds has caused the machining industry to face new processing problems. Because this micromachining with very small tools is fundamentally different from machining with large gauge tools.
In order to reduce manufacturing costs, large quantities of micro-components are manufactured using molds. At present, the processing of such small molds is a strong growth area. Since the mold has extremely high requirements on precision and surface quality, the mold is manufactured in a single piece or in a small batch. To be flexible and economical to produce, this makes the micro-milling process a particularly important position. Micro-milling has many advantages over EDM and laser machining:
1. It can process hardened tool steel;
2. Flexible manufacturing of complex geometric surfaces;
3. Existing CAD/CAM systems can be utilized;
4, can get a good surface quality;
5. A relatively low equipment investment.
Therefore, in the manufacture of micro-molds, the micro-milling process can be used to manufacture various cores flexibly and precisely using NC-5 axis (or 3-axis) high-speed machining centers or micro-milling machines.
Milling of very small diameter milling cutters, the diameter of the milling cutter is usually between 0.1mm and 2mm, and the milling cutter has two milling edges. Considering the small diameter and poor rigidity of the milling cutter, the tool material is generally made of ultrafine particles (0.2 祄 ~ 0.5 祄) cemented carbide, which is composed of WC-Co and bonding materials, and can be evenly obtained during sintering. The structure has the advantages of high hardness, good toughness, high fatigue resistance and good impact resistance, so it is suitable for making small diameter milling cutters and is used for hard milling.
In order to reduce the friction between the milling cutter blade and the workpiece and improve the wear resistance and thermal stability of the milling cutter, the milling cutter is coated with a hard coating of 1 祄 3 祄 thick, for example, a PVD coating process can be used. A hard material coating such as TiAlN or TiCN or a diamond coating using a CVD coating process. To enhance the rigidity of the micro-milling cutter, the milling cutter has a tapered structure and a cylindrical shank.
Due to the small diameter of the micro-milling cutter and the poor rigidity, the plane moment of inertia decreases with the diameter of the milling cutter. Therefore, in micro-milling, the milling cutter can only withstand a small cutting force and torque. Therefore, the milling should use a small amount of feed per tooth, depending on the diameter of the milling cutter and the hardness of the workpiece material. For a diameter of 0.5/100 to 3/100 of the milling cutter, excessive feed can cause the tool to break.
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