viper process use in marking aircraft engine

Aircraft engine manufacturing is a highly competitive industry, market demand for cyclical, it requires a lot of investment and development costs. Although complexity means that the finished engine aircraft and airframe manufacturers must bear the time interval between ordering and delivery of long history, but competitive pressures are forcing people to look for more sophisticated and faster response of the market to make The method of manufacturing. In the United Kingdom, the engine manufacturer Rolls-Royce has a unique process of this challenge response - Flexible grinding of nickel alloy wheel with equipment processing center. 

This process is referred to as the "Viper", "Vitreous Improved Performance Extreme Removal" Abbreviated from. The 1990s as a method for processing nickel alloy alternative CBN super abrasive and strong creep feed grinding technology, high-performance technology developed. The process has been applied in the Rolls-Royce factory, but it is the most comprehensive application of a worm blade factory in Derbyshire city, which has 10 processing center for the Viper. The process plant will each set to high pressure worm gear leaves from order to delivery time reduced from about 100 days to 15 days.

Viper grinding process involves the use of pre-formed small diameter grinding wheel - used on CNC machining centers "tool" 
The various features used in precision machining nickel alloy worm blade

Viper grinding diameter of not more than 200mm of alumina grinding wheel, grinding wheel mounted on the after special adaptive processing Makino (Makino) or Bridge Fort (Bridgeport) machining center spindle. Replacement of the wheel with the ordinary cutter. For a specific blade, the processing "cedar" root form "shroud" end features may need to 15 different types of wheel shape. 

Rolls-Royce claims, under suitable conditions, the process of metal removal rate can reach 80 mm3 / s / mm of wheel width. This is in the ordinary grinder of nickel plated CBN grinding wheel by super abrasive machining technology machining nickel alloy metal removal rate can be achieved. The process can also fining alternative way much higher than other metal removal. 

Phil Hopton, Rolls-Royce worm Systems Director. He said : Used strong creep feed grinding technology to the processing of these characteristics. Goal of this technology is to be mass-produced, machine set-up times must be counting days, each blade needs to be completed through a large machine to processing. These. process kinds of technology, high-pressure blade production is a bottleneck problem exists. "the company consider the use of CBN grinding wheel as an alternative, but the the Viper process in terms of performance to achieve a great improvement, thus changing the entire blade processing mode. 

The Viper's origins can be traced back to the Rolls-Royce engineers Peter Hill, he noticed that the special strength creep feed machine can sometimes be in a continuous wheel dressing satisfactory processing in order to maintain the shape and sharpness case. Subsequently, in a high pressure coolant cleaning tool cutting edge titanium milling project experience, he considered such a possibility, that the development of a suitable general milling and drilling tool change machining center will set become one of the "pure grinding wheel grinding process.

This grinding device equipped on a horizontal machining center. Equipped with a suitable for the job 
Machine tool changes including the installation of the dresser, and coolant nozzle CNC control

Cooperative development projects carried out by professional manufacturers Tyrolit, machining center manufacturers the Makino and Bridge Fort consumable parts and grinding up to four years, the company developed last today. May Unsurprisingly, the most important factor proves grinding consumable parts and coolant. The project also eliminate people suspected of ordinary milling spindle can cope with the grinding wheel imbalance. 
Mr. Hill said: "We have to consider a lot of factors and we must make sure that the open wheel connection not grip the fine grinding produces chip must also develop a support ratio of high velocity and high pressure coolant system and coolant able to withstand, but does not produce foam in the case of fine filtration process. " 

The coolant filter the Viper grinding success is very critical. The process uses a specially developed nozzle to a pressure of 1000psi of sprayed cooling liquid and interface maintains a precise angle relative to the grinding wheel and the workpiece. By filtration and removal of particles above 10 microns in diameter, Viper process thus avoiding to produce corrosion of the grinding wheel cutting edge. 

In the grinding process, with the cooling liquid can reduce the chip temperature, to prevent the fine chips are adhered to the grinding medium, while the jet may also be washed clean the cuttings. This can prevent the wheel "passivation", thus obviating the need for intermediate trimming. This in turn helps to keep the lower wheel wear rate, thus the "tool" of the small diameter grinding wheel life can be maintained within the acceptable range. 

In order to a processing center for Viper grinding process, the need for a large number of manufacturing changes. These changes include the coolant delivery, installation, and sealing and protection of the diamond dresser problems. From the process in this regard, the need to maintain the same cooling liquid transport track, while using the the interpolation axis grinding machine up to 5. Makino company has developed a two-axis CNC-controlled coolant nozzle mounted on the spindle end around. Provided by an axis (U) of rotation, so as to either horizontal grinding the vertical grinding may be performed; nozzle radial positioning provided by another axis (V), thereby to compensate for wear of the grinding wheel - this wear the machining cycle sometimes the grinding wheel diameter reduced by half. 

Even after these changes, the Makino A55 machining center equipped this way, the cost is still lower than the cost of the strong creep feed grinder. Moreover, with the tool change function, all characterized by grinding can be done in two operations, and by means of the machining center has a flexible, between different parts of the conversion can be achieved within 2 hours, or less than 2 hours . 

Look ahead 

In the the Viper process is complete, the challenges faced by the Rolls-Royce is a comprehensive infer leaf processing and the advantages of the process. 

Hopton said Mr. : "Viper technology has advantages help us to move forward the process of reform. Worm blade machining factory Go to the sophisticated manufacturing process from batch manufacturing machining practices as well as the development of the worm blade machining method has 'Rolls-Royce production systems' practices and methods for providing a model for reducing customer from order to delivery between the time it is very useful. " 

British subcontractor to provide services to Rolls-Royce, a common saying is "40-day engine. Today worm blade machining process played a major role in achieving the goal. Pressure vane 15 days of the order to the delivery time, in fact, only 4-5 days of processing time, and have found that the time can be further shortened. 

Each of the engine's high-pressure the worm leaves, such as Rolls-Royce Trent, it generates horsepower racing engines to produce the same. These blades are composed of the finished engine with about 28% of the blade, and the company has maintained its production in-house. Worm gear blade factory in Derbyshire city built on a the same high-tech precision casting factory near the casting plant mainly produces leaves blank, at the same time near a heat treatment plant operated by a third party contractor. Only to complete the operation is not in the factory floor is coated with a special heat-resistant coating on the finished blade.

In the the Viper grinding machine unit, a robot in the processing center and 
Transmitted between the blade is mounted on the jig in the coordinate measuring machine

Blade machining and design in Derbyshire City an expansion of the building, through a glass wall separates between them. Relatively low due to the cost of installation of a the Viper production unit of Rolls-Royce has a whole production line for leaf development. Traditional designers from production machinery must "request or borrow" time to develop new products, but such a development unit to change this situation. Therefore, Hopton said: "We hope that the convenience of the new aspects of the design and production of high pressure vane can bring great benefits." 
The worm leaves processing in manufacturing systems and methods development is the team of led by Mark Hulands, responsible for the, now he is the manager of the worm gear systems company Rolls-Royce sophisticated manufacturing. The President of Hulands, an important goal is to keep the production flow, to the advantage of the Viper process can not be interrupted in the entire manufacturing process. In order to achieve this, the team is scheduled to target offline for part clamping and automate this process when possible. The team also strive to avoid reliance on batch processing technology. One such technique is the zinc alloy to encapsulate the blade, so that during the grinding process can be more easily clamping. This encapsulation not only with the queue, and also must be implemented by the two-stage process of removing. 
The plant currently has 5 of the same production lines (one for development, for the production of four), and also set aside space for the sixth production line. Each production line and equipment are the same, both for the blade machining, and claims can be processed in any one of the 18 kinds of blade type. The general routine includes four stages, including cedar shaped grinding one Viper unit and the shroud, and the seal band and the opening shroud cooling device EDM gas film and the shroud portion EDM drilling of the cooling holes, the pair of positioning pins EDM removal processing, and the TIG welding of the hole of the core used in the casting process, the blowing hole drilling, and final polishing process on a CNC surface grinder . 

Flexible process 

The the Viper unit includes two suitable Viper technology Makino A55 machining center as well as two Mitutoyo coordinate measuring machine (Mitutoyo), all of these machines are equipped with Fanuc (Fanuc_ robot input of the unit using a a scroll conveyor belt - with a video installation, and jig identification system. 

The blade casting is a separate standard code, with a customer-designed air metering station to install them in a flexible fixture, in order to be processed. The blade through a casting pin is fixed in the fixture (fixed position of the bottom of the cedar shaped portion), but can be by the freedom of movement of the mechanically fixed ball joints. The feature position on the terminal by the metering table with respect to the blades of the gas film portion the best-fit analysis, and when all the measured characteristics are automatically in its nominal position within the range of 30 microns at the position clamping. Located at the input to the imaging system on the conveyor blade will automatically read the serial number and jig ID, automatically storing data (to be processed for each blade automatically created) in the history file.

For grinding the blade is mounted in a toggle-type flexible fixture. 
This conditioning systems through customer development the blade shape relative to the correct clamping parts cedar shaped shroud end. 
When the optimum adjustment, the fixture is automatically lock in place

The characteristics of the blade is completed by two operations, a total of 17 minutes. First 12 minutes of operation, the second operation of 5 minutes, the unit allows a single machine to complete the two operations, and let the other only the first operation, in this way to be balanced on the machine workload . With the clamping position of the the Erowa fixture on the machine tool and the clamping device, the positioning of the workpiece in the processing center and the coordinate measuring machine can be highly repetitive. All processing by using a series of pre-formed the wheel completed grinding process. These wheels are installed in the same manner as with ordinary cutter shape model for a computer-generated checks, and in the clamping process. 

After the completion of the first operation, the blade to be checked on a coordinate measuring machine. Rolls-Royce at this stage adaptive processing software automatically with characteristic, it can automatically adjust the parameters of the CNC program for the second operation. Terry Shaw, members of the group, said the process to achieve a 1.42 Cpk tolerance for cedar root the shape ± 14 microns. 

After the completion of the grinding, the various parts are cleaned, and then sent them to Charmilles EDM machine tools - for processing sealing tape slot and opened shroud cooling characteristics. Compare the unique aspects of the operation is the Rolls-Royce normal EDM practices turn: Part jig is mounted to the spindle sleeve, for machining the electrode is mounted to the fixed position in the cutting fluid within the three. In a stacked manner for processing blades are mounted on the four universal fixture. These fixtures are then mounted on the electrode replacing apparatus of the machine tool, and extracted by the spindle sleeve and the workpiece, and using the positioning function of the C-axis is aligned with the desired electrode. All clamping can thus be done in the case of off, thereby improving the processing efficiency. 

Similarly, the cooling hole EDM drilling must be carried out in a blade clamping and also to achieve a fully automated. Each production line 12 EDM drilling machine tools, they are arranged in a fully automatic unit. Each machine can be used equipped with a plurality of preformed tubular brass electrode apparatus of one type of hole drilling. The drilling process with deionized water as a dielectric to achieve a high drilling speed. When drilling is completed, through the eye and video scan mode to check each leaf, in order to determine the required grooved its appearance and the correct position - in less than 25 microns. And then the blade sent for final finishing operation. 

The President of Hulands said, an important advantage of the entire system having a high flexibility. He said : Within 2-3 hours of the production line to switch from one type of leaf processing to another type of volume can also be processed in technology as a blade. "(End)

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Centerless grinder centering grinding

Workshop specializing in cylindrical grinding often need to convert the type of work, the workpiece processing conversion from the inside diameter, outside diameter grinder centerless grinder. If you can understand the rational behind this conversion, then be able to determine the centerless grinder exactly where to play its role. 

When a part is sent to the grinding workshop process, the parts have been milling, turning, heat treatment, and other operating process. The process will create more added value to the part, and the time spent by each process may be more than people expected. In addition, there is the pressure of competition from other advanced technology. However, is located in the Pennsylvania State M & S Hatboro grinding company boss Mr. John Shegda this with confidence, because the kind of work he just "Shoudaoqinlai" things, in fact, this competition mainly from turning technology his processing plant is in a flourishing excellent situation. Since 2006, the scale of his processing plant has been expanded three times, most of its processing equipment is an upgrade. 

The recent success of the workshop, the majority should be attributed to the correct allocation of its resources. They should know that when the deployment of forces, centerless grinding technology in cylindrical grinding, and should be used when other methods. In order to maximize the level of high-precision machining of workpieces and profits, the workshop is usually associated with outside diameter, inside diameter machining some adjustments to the workpiece processing on the latest purchase of through-feed centerless grinder. In order to achieve this aim, the grinding subcontractor demonstrates not only the most effective level of processing centerless grinder, but also demonstrates today centerless grinder has a variety of functions.

Figure 1 Monza 410 Centerless Grinder, it can make the workshop to the geometry of the high precision control parts, in order to achieve the high-end processing requirements. After completion of this process, the following work is relatively simple

Due to a lack of understanding of the dynamics of this process and therefore can not understand the high-precision grinding technology with amazing force. However Shegda Mr. abandoned this the grinding concept, so this technology to be able to play the biggest role. He and his 14 employees in a more logical way to apply this type of grinding technology. They learned Mr. Meron Shegda left their analytical techniques and knowledge of grinding, opened the business in 1957. Since 1990, Mr. the John Shegda President, and Mark Shegda incharge of M & S Mr. Meron Shegda, a chess enthusiast, his interest in the game to help him further improve his ability to analyze, proved his ability to create this business is very beneficial. 

Mr John Shegda said: "what we have done and know everything should be attributed to my father and he is a person of the smartest people I know." In those days, companies rely entirely on in his mind, as well as a variety of processing equipment, including CNC CNC machine tools , automatic machine and manual machines. The company's business scope includes all types of cylindrical grinding, mainly to provide services for the medical and aerospace industries. M & S company can be processed for these industries grinding parts in any form, including a plurality of processing steps, various angles, taper and radius. About 500 customers, including many of the machining workshop, M & S, to help them processed again, to amend certain parts of the non-circularity, and also called for the speedy delivery. 

Since recognized the centerless grinding performance, M & S started to apply it in practice. Fact, centerless grinding technology to further improve the confidence of the processing plant, enabling them to successfully complete the processing tasks in accordance with thehigh-precision roundness and tolerances size requirements. 

Complex work is required to complete Shegda President and his staff need to complete the task. These high-precision workpiece about 1 to 10,000, its roundness and concentricity demanding precision up to 0.02in (1in = 25.4mm). 

Shegda President explained: "We undertake most new workpiece diameter and roundness tolerances size requirements is very high (generally parts of the aviation industry), and some even parts of the medical industry, small shape, the processing required to achieve stunning proportions. " 

Sophisticated technology and the basic principles of 

Centerless grinding process grinding type of workpiece is not a problem, and will succeed. , M & S whenever possible will be using this processing method. 
Shegda Mr. explained: "The most important is a centerless grinding faster, generally speaking, this process has a high machining accuracy, because the machine does not need to run to the very small incremental steps. Therefore, we are able to control tolerance dimensions. " 

Centerless grinding and cylindrical grinding process is the difference between the workpiece without mechanical restrictions. Cylindrical Grinder is generally the workpiece clamping into the top or chuck, the workpiece against the grinding wheel rotating grinding, centerless grinder without any clamp the workpiece center point. It relies on the principle of the interaction force between the grinding in the three critical components, these three components are wheel, the adjusting wheel and the workpiece vane. 

In the centerless grinding process, the workpiece paddles used for the outer diameter of the workpiece support. Workpiece blade plate is mounted on the high speed grinding wheel and a smaller diameter between the low-speed regulating wheel. In order to make the workpiece to achieve the purpose of rotating and grinding, the workpiece paddles must be installed to a position, i.e., the centerline of the workpiece should be located in the center line of the grinding wheel and the regulating wheel. 

About 2 years ago, the shop has made ​​a strategic investment, in order to further optimize the centerless grinding process. The shop purchased a Monza 410 CNC CNC runs through feed centerless grinder. Prior to this, only 6 of the workshop revamped centerless grinder.Although these daily processing accuracy of the transformation of the grinder can be maintained within 0.0001 inch tolerances size range, but it is impossible to achieve the requirements of the ultra-precision tolerances, because the processing requirements of these parts are the medical and aerospace industries to their proposed 's. In order to be able to undertake high precision machined parts, the workshop has been added to a Monza 310 type through feed centerless grinder for processing flat head pin, flat head reel and diameter of0.020in a miniature medical equipment parts. 

Mr. Shegda said: "If we had the machine for roundness, flatness or the diameter of the dimensional accuracy of the struggle, we will not be able to deal effectively with such a demanding high-end workpiece. Monza centerless grinder so that we are able to compare geometric accuracy of the level of precision control components to meet the processing requirements, reduce the complexity of the workpiece in any case, the work of this nature is still not able to so easily accomplished, but we can at least parts inherent in the problem and focus on, and not to deal with the limitations of the equipment. " 

For the processing plant, part of the value in its new grinder has quickly debug settings. In fact, the operator generally can be completed within 15 ~ 20min the centerless grinding workpiece basic debug settings. Whether in the old-fashioned machine and Monza centerless grinder quickly debug settings workpiece, M & S Company is very critical, because each machine may need 6 to 8 times the workpiece chucking debugging daily. 

Mr. Shegda said: "If, for us, according to the nature of our work and constant debug card number of matched only spend 1h to complete everything is realistic." 

M & S is not overly dependent on a clever arrangement, but Monza 410 type runs through feed centerless grinding machine to complete the work. This machine has the characteristic of "Strengthening correction", so it allows the operator to the operation of the machine running the adjustment and correction diameter size. 

The roundness of the wheel type, condition, and the amount of processing materials require cutting also affect the the debug settings important factors. Mr. Shegda reason that you want to configure through the feed centerless grinder reasons, it is hoped to have a "back-up" dimensions in a precision workpiece machining process. 

Mr. Shegda explained: "The worst thing is to be able to do to maintain the consistency of the size, stop using it throughout the feed centerless grinder in order to be able to effectively to reach 0.000 01in incremental level precision, we can Monza 410 type centerless grinder on the precise control of size, without having to stop the operation of the machine. " 

In addition to the basic knowledge to understand centerless grinder and appropriate evaluation of the equipment needed for the implementation of the process operation, the processing plant staff must also understand the rational allocation of equipment, which have a great impact on profit margins and the overall effectiveness of the work on the shop floor.

Even workshop outer diameter grinding is considered the best means of processing, the roundness of the processing by this method can be achieved ppm 10 ~ 20in level, relative to other methods, can maintain high accuracy, but The two methods are not necessarily suitable for all processing. Mr. Shegda found that some customers often mistakenly believe that they only need the kind of grinding between the thimble, but in fact, they need the processing capacity centerless grinder. For example, for a relatively large part of the length and diameter of the outer diameter grinding may generate some problems.

Figure 2 is for a relatively large length and diameter of the workpiece using the grinding of the centerless grinder, such as the following precision punch and die shows the kind of parts

Shegda President explained: "If parts need grinding long very thin, so it will be more difficult to cylindrical grinding. Contrary, centerless grinder will be handy if one part of the diameter of 0.250in, length 10in total outside diameter tolerances processing 0.0001in,processing will become a "nightmare" in the cylindrical grinder If the parts with a flat head above, we can use the through-feed centerless grinding machines, grinding will much more simple and easy, even on a larger infeed machine processing key is the part three sides must be in the form of support: The carbide alloy paddle is located in the lower part of the adjustment wheel on the side, the grinding wheel is located in another side as long as three support surface in a normal position, then in theory, grinding a direct round bars should not be much of a problem, of course, the theory is, after all, are very different from the actual, but If you truly understand the processing of parts, then it must be able to obtain a very high tolerance dimensional accuracy. " 

Grinding pursuit of a greater challenge, suggesting that this process with Hard Turning compete and contend. For centerless grinding, the main competition is not from the grinding workshop, but from other competitive technologies. 

Shegda President explained: "We think Hard turning is a very 'competitors', because now processing plant can effectively turning machining after heat treatment of steel workpiece machining accuracy of up to 0.0005 in many cases even processing can achieve higher accuracy in order to develop and expand our business, this process actually allows us to shift to a more critical and more challenging work. now, only those who are able to achieve high accuracy and high quality the work, as well as the breakthrough technology of the times to be successful.

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The choice of high-speed cutting tool

The high-speedcutting tools (High-Speed ​​Machining, HSM) is to move rapidly in the 1990s, the practical application of advanced processing technology, usually refers to vertical milling under high spindle speed and high feed rate, international processing industry in the aerospace manufacturing industry, mold , car zero Shijia workers, as well as precision zero Shijia workers, and other fields are widely used. High-speed milling can be used for cutting, such as aluminum, copper metal and hardened steel, titanium alloys, high temperature alloys and other difficult-to-machine materials, as well as carbon fiber, plastic and non-metallic materials processing. For example, in the processing of aluminum alloy aircraft parts, surfaces and complex structure, material removal as high as 90% -95%, the use of high-speed milling everyone to improve production efficiency and precision. The high-speed cutting tool technology is one of the key technologies to achieve high-speed machining. With the substantial increase in cutting speed cutting tool material and geometric parameters, arbor structure and cutting process parameters are different from the requirements of the traditional speed cutting right choice and optimization of the parameters of the tool, to improve processing efficiency and quality to extend tool life, reduce processing costs will play a very critical role.

1 tool material

  High-speed milling tool materials carbide coated tools, cermet, ceramics, cubic boron nitride (CBN) and diamond tools.

  Carbide: high-speed cutter usually fine grain products or ultrafine grain products Carbide the (product grain size of 0.2 ~ 1 μ m), selected according to the material to be machined tungsten cobalt carbide or tungsten titanium cobalt classes.

  Coated tools: a large number of high-speed milling of coated tools, matrix high speed steel, carbide rain I ceramic, carbide mainly. TiCN, TiAIN, TiAICN, CBN, Al2O3, CNx coating material, commonly used multi-layer composite coating, such as: TiCN + Al2O3 + TiN, TiCN + Al2O3, TiCN + Al2O3 + HfN, TiN + Al2O3, TiCN, TiB2 , TiAlN / Tin and TiAlN. Latest development TiN / AIN nano-coated tools are also suitable for high-speed cutting.

  Cermets: high wear resistance of TiC-based cermet (TiC + Ni or Mo). High toughness of TiC-based cermet (TiC + TaC + WC + Co), Enhanced TiCN based cermet (TiCN + NbC), compared Carbide improve the high temperature properties of the tool, suitable for high-speed machining alloy steel and cast iron.

  Ceramic Tool: ceramic tool is divided into alumina ceramics, silicon nitride ceramics, and composite ceramics of three types, having a high hardness, high wear resistance, thermal stability. Al2O3 ceramic accounts for about 2/3, this ceramic tools for machining steel; about 1/3of Si3N4-based ceramic, this ceramic tool is more suitable for high-speed milling of cast iron; Si3N4-Al2O3 composite ceramics with high strength and fracture toughness, is not suitable for the machining of steel, can be used for high speed roughing of cast iron and nickel-based alloys.

CBN: CBN tool has a high hardness, high heat resistance, high chemical stability and thermal conductivity, but with lower intensity. Score by weight, low content of CBN (50% ~ 65%) can be used for the finishing of hardened steel; high content of CBN (80% ~ 90%) can be just high-speed milling of cast iron, hardened steel roughing and semi-finishing .

  Diamond: points natural diamond and polycrystalline diamond, high-speed milling of polycrystalline diamond, usually used for high-speed processing of non-ferrous metals and non-metallic materials.

  High-speed milling, the most widely used solid carbide cutting tools, followed by machine clip carbide cutting tools.

2 tool structure

Figure 1 is a typical high-speed milling tool

  Figure 1 shows some typical high-speed milling cutter is divided into two types, the overall style and machine folder. Small diameter cutters generally use a whole large diameter cutter machine clip. High-speed machine tool diameter limit, the overall high-speed cutter in the factory after the balancing test, use more convenient machine clip after clamping the blade dynamic balance, so the overall style of the more common. The machine is relatively low speed, can be used to provide greater torque machine clip cutter. Balance Grade clip cutting tools in high speed machine, it should be noted that the tool, as well as the maximum allowable speed.

  Cutter pitch is defined as adjacent to the periphery of the two knife between the teeth to the distance, is influenced by the number of teeth of the cutter knife. Means more short pitch cutter tooth-and middle-chip space, allowing high metal removal rate, generally used for cast iron milling and milling medium load steel, usually as a high-speed cutter preferred. Large pitch cutter teeth less chip space, commonly used for roughing and finishing of steel, and prone to vibration occasions. Small the superdense pitch chip space, can withstand very high feed rate, suitable cast iron intermittent surface processing, the small cut cast iron roughing and steel deep processing.

3 shank structure

  Usually when the maximum speed of the machine to achieve 15000r/min HSK high-speed cutter arbor, or other types of short handle Arbor. HSK shank for positioning structure, providing links to the machine tool standard machine under tension, to ensure Arbor short cone and end face close coordination with the machine.

  Arbor clamping tool side with spring clamp type, hydraulic clamping and thermal expansion type, Weldon is difficult to guarantee Cutter balance should not be used in high-speed milling. Figure 2 for the elastic clamping, hydraulic clamping and thermal expansion Arbor schematic diagram. Thermal expansion structure is simple, reliable clamping, high concentricity transfer torque and radial force, rigid foot, balancing arbor structure is currently the most development potential.

Figure 2 arbor chuck the form

  Knife hole and shank of thermal expansion Arbor chuck interference fit, to adopt the the dedicated thermal expansion device handling tool, the general use of the inductive heating or hot air heating Arbor knife holes true diameter expansion, and then insert the knife handle knife After cooling aperture contraction to grip the knife handle. The above three tool clamping manner, the clamping of the tool to the thermal expansion the highest mounting precision, while providing more fire torque. Especially in the application of a small-diameter tool for high speed machining, thermal expansion, clamping advantages.

4 processing technology and cutting parameters

  Is generally not recommended in high-speed milling end mills using flat-bottomed. This is because the flat bottom end mill cutting tool tip site to the chip flow interference chip deformation, while the shortest effective length of the cutting edge, the tool nose fire by force, cutting temperature, resulting in rapid wear. Larger tool nose radius should make salmon under the conditions of the process allows for high-speed milling, because the average cutting thickness and main angle decreased with increasing the corner radius end mill, at the same time the tool increased axial force can take full advantage of the axial stiffness of machine tools to reduce tool vibration deformation and cutting.

  Therefore, commonly used in high-speed milling larger corner radius end mills (ball end cutters or circular blade mosaic tool), and axial depth of cut is generally not to declare more than the nose radius. Related to the radial depth of cut material selection and processing can be used to improve processing efficiency, light alloy of aluminum like the larger radial milling depth, and somewhat less for steel and other processing materials should choose smaller radial The milling depth slowing tool wear.

  The determination of the amount of high-speed milling machining efficiency is the main consideration, the machined surface quality, tool wear, as well as processing costs [5]. Different tool machining different workpiece material, processing and consumption vary significantly, the No complete processing data. High-speed milling in aluminum processing technology is more mature, generally based on the actual selection of cutting tools and machining object reference tool vendor processing the amount of choice. The general election express the principles of the medium to the amount of feed per tooth fz, smaller axial depth of cut ap appropriate radial depth of cut ae maintain high cutting speed and spindle speed.

5 Conclusion

  High-speed machining is the inevitable trend of development of the mechanical manufacturing industry to accelerate its marketing application will create huge economic benefits. The high-speed cutting tools technology has decisive for the development and application of high speed cutting technology Chuan, therefore, the research and development of high-speed cutting tool technology has great significance. With the development of advanced manufacturing technology and materials technology, coated tools, superhard material tools, ceramic tools will be widely used, the system of high-speed cutting tools are maturing, becoming an important part of promoting high-speed machining.

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