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车削-切槽 & 切断加工
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刀片磨损原因及解决方案
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孔加工
钻削刀片磨损原因及解决方案
整体硬质合金钻头
可换头式钻头
可换刀片式钻头
磨损类型
×
后刀面磨损
后刀面磨损
原因
切削速度高
硬质合金牌号不耐磨
解决方案
检查所用刀具形状是否正确
提高冷却液压力
更换为硬度更高的牌号
提高冷却液里油浓度百分比
降低切削速度。***提高进给
×
月牙洼磨损
月牙洼磨损
原因
刀片切削区域切削温度过高,压力过大
解决方案
降低进给
检查所用刀具形状是否正确
×
塑性变形
塑性变形
原因
切削温度过高
解决方案
检查切削参数
降低进给
提高冷却液压力 / 冷却液流量
采用硬度更高的牌号
检查所用刀具形状是否正确
×
热裂
热裂
原因
切削区域表面温度变化太大,断续切削,或冷却液供应产生变化
解决方案
提高冷却液压力 / 冷却液流量
提高冷却液中油含量百分比
×
切削刃外侧破损
切削刃外侧破损
原因
更换刀片切削刃前,刀片过度磨损
对于该应用而言,刀片牌号及几何形状都太弱了
刀片载荷过大
刀片已形成了积屑瘤
解决方案
检查钻头径向跳动
降低进给率,提高切削速度
检查刀具及工件的夹持刚性
检查定位槽夹持力是否过低,更换钻杆
提高冷却液压力
采用外冷加工时,调整冷却射流方向使其更精准
×
积屑瘤
积屑瘤
原因
切削区域温度太低
负型刀片
加工材料粘性高,如低碳钢,不锈钢及铝
解决方案
提高进给
提高切削速度
提高冷却液压力
检查冷却液中油含量百分比
×
切削刃崩刃
切削刃崩刃
原因
硬质合金牌号不耐磨
刀片已形成了积屑瘤
切削液供应不足
解决方案
降低进给率
提高切削速度
提高冷却液压力
采用外冷加工时,调整冷却射流方向使其更精准
更换为不同形状的钻头
检查刀具及工件的夹持刚性
×
横刃崩刃
横刃崩刃
原因
横刃跳动太大
结合了高进给 & 低切削速度
解决方案
降低进给率并提高切削速度
检查横刃错位不超过0.02mm
检查刀具及工件的夹持刚性
检查定位槽夹持力是否过低,更换钻杆
×
切削刃外侧崩刃
切削刃外侧崩刃
原因
径向跳动太大
切削液供应不足
解决方案
检查钻头径向跳动
降低进给率,提高切削速度
检查刀具及工件的夹持刚性
检查定位槽夹持力是否过低,更换钻杆
提高冷却液压力
采用外冷加工时,调整冷却射流方向使其更精准
×
棱边磨损
棱边磨损
原因
切削速度过高
硬质合金牌号不耐磨
径向跳动太大
解决方案
检查所用刀具形状是否正确
检查 刀尖跳动T.I.R不超过0.02mm
降低切削速度
提高冷却液压力
采用外冷加工时,调整冷却射流方向使其更精准
检查并提高刀具及工件的夹持刚性
检查定位槽夹持力是否过低,更换钻杆
×
Flank Wear
Flank Wear
原因
High cutting speed
Low wear resistance carbide grade
Remedy
Check that the correct geometry is used
Increase coolant pressure
Change to harder grade
Increase oil concentration presentage
Reduce cutting speed.*** increase feed
×
Crater Wear
Crater Wear
原因
Excessive cutting temperatures and pressures on the top of the insert.
Remedy
Reduce cutting feed
Check that the correct geometry is used
×
Plastic Deformation
Plastic Deformation
原因
Cutting temperature is too high
Remedy
Check cutting parameters
Reduce cutting feed
Increase coolant pressure/volume
Use harder grade
Check that the correct geometry is used
×
Thermal Cracking
Thermal Cracking
原因
Excessive variations in surface temperature, intermittent machining, or variations in coolant supply
Remedy
Increase coolant pressure/volume
Increase oll concentration presentage
×
Corner Fracture
Corner Fracture
原因
Caused by excessive insert wear before indexing the insert
The grade and geometry could be too weak for the applications
Excessive load on the insert
Built-up edge has been formed on the insert
Remedy
Check radial run-out
Reduce feed rate increase the speed
Check tool and part clamping rigidity
Check if pocket gripping forces is too low, replace the holder
Increase coolant pressure
Improve jet direction in case of external coolant supply
×
Built-up Edge
Built-up Edge
原因
Cutting zone temperature is too low
Negative cutting geometry
Machining of very sticky materials such as low-carbon steel, stainless steels, and aluminum
Remedy
Increase the feed
Increase cutting speed
Increase coolant pressure
Check oil percentage in the coolant fluid
×
Edge chipping
Edge chipping
原因
Low wear resistance carbide grade
Built-up edge has been formed
Insufficient cutting fluid
Remedy
Reduce feed rate
Increase the speed
Increase coolant pressure
Improve jet direction in case of external coolant supply
Change to different geometry
Check tool and part clamping rigidity
×
Chisel Chipping
Chisel Chipping
原因
Chisel run-out is too big
Combine of high feed & low speed
Remedy
Reduce feed rate and increase the cutting speed
Check that chisel misalignment does not exceed 0.02mm
Check tool and part clamping rigidity
Check if pocket gripping forces is too low, replace the holder
×
Land Wear
Land Wear
原因
Cutting speed too high
Low wear resistance carbide grade
Radial run-out is too big
Remedy
Check that the correct geometry is used
Check that T.I.R run-out does not exceed 0.02mm
Reduce cutting speed
Increase coolant pressure
Improve jet direction in case of external coolant supply
Check and improve tool and part clamping rigidity
Check if pocket gripping forces is too low, replace the tool body
×
Corner Chipping
Corner Chipping
原因
Radial run-out is too big
Insufficient cutting fluid
Remedy
Check radial run-out
Reduce feed rate increase the speed
Check tool and part clamping rigidity
Check if pocket gripping forces is too low, replace the holder
Increase coolant pressure
Improve jet direction in case of external coolant supply
×
Flank Wear
Flank Wear
Cause
High cutting speed
Low wear resistance carbide grade
Remedy
Reduce cutting speed
Increase coolant pressure/volume
Choose better wear resistance grade
Increase oil concentration presentage
×
Crater Wear
Crater Wear
Cause
Excessive cutting temperatures and pressures on the top of the insert
Remedy
outer insert:
Reduce cutting speed
Choose better wear resistance grade
Change to different chipbreaker
inner insert:
Reduce feed rate
Change to different chipbreaker
×
Plastic Deformation
Plastic Deformation
Cause
Cutting temperature is too high
Remedy
Reduce feed rate
Choose better wear resistance grade
Increase coolant pressure/volume
Choose diferent chip-breaker
×
Thermal Cracking
Thermal Cracking
Cause
Excessive variations in surface temperature, intermittent machining, or variations in coolant supply
Remedy
Use tougher grade
Increase coolant pressure/volume
×
Edge Fracture
Edge Fracture
Cause
Caused by excessive insert wear before indexing the insert
The grade and geometry could be too weak for the applications
Excessive load on the insert
Built-up edge has been formed on the insert
Remedy
Use tougher grade
Reduce feed rate
Increase coolant pressure/volume
Change to different chipbreaker
×
Built-up Edge
Built-up Edge
Cause
Cutting zone temperature is too low
Negative cutting geometry
Machining of very sticky materials such as low-carbon steel, stainless steels, and aluminum
Remedy
Increase cutting speed
Change to different chipbreaker
Reduce feed rate
Increase coolant pressure/volume
×
Chipping
Chipping
Cause
Low wear resistance carbide grade
Built-up edge has been formed
Insufficient cutting fluid
Remedy
Choose tougheer grade
Reduce feed
Increase coolant pressure/volume
Change to different chipbreaker
×
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