Die steel processing: milling with high feed rate
What is the amount of cutting when machining metal? How high should the cutting speed be? This is the most common problem in today's mold shop, and this leads to the next topic: high-feed metal cutting. High-feedrate machining tools give you the advantages of high productivity and affordability (Figure 3). In fact, when you use a high feed rate tool to cut metal, you can achieve 2 to 3 times faster than using a normal milling cutter. Many of the new CNC machines produced today are relatively rugged and durable, and powerful, providing a strong backing for engineers using high feed rate technology.
Figure 3 Tool with high feed rate allows you to machine at a faster rate and allows engineers to machine with higher efficiency
High feed rate milling usually uses a variety of features of carbide inserts for efficient machining. In the past milling applications, many tooling equipment often used round inserts. Recently, inserts made by many tool companies have achieved higher feed rates than conventional round inserts. In order to achieve high feed rate milling successfully and safely, it is critical to master the various features of the insert.
Inserts with high feed rates usually have special geometries. In milling with high feed rates, the most common is the use of triangular inserts. Such inserts tend to have a larger tip radius, a thicker blade, and a very advantageous smaller approach angle (>45°). The combination of these features allows engineers to apply higher feed rates (with smaller depth of cut). In some cases, the feed rate of the milling cutter can be as high as 0.118 in/tooth.
Several knives on the market even offer durable double-sided negative blades. These durable double-sided negative blades enhance the processing power of the insert. Nowadays, the use of negative-direction milling inserts with forward geometry is a very popular milling method.
A common feature of inserts is that they are generally of relatively thick size and have a forward geometry. The use of double-sided inserts is very advantageous, and the main reason is that you can double the effective cutting angle of the insert (this is a fashionable green way of working). In addition, more efficient cutting edges can be used, so today's inserts have a more powerful cutting function. If used properly, engineers can actually increase the life of the tool when using a negative milling cutter. Practice has proved that in the design process of some high feed rate milling cutters, the tools with negative design mode can actually reduce the cutting force of the tool compared with their opposite single-sided tools.
In the evolving mold manufacturing industry, it is crucial to maintain competitiveness and increase productivity and productivity. Choosing the right tool will give the machine full performance, allowing moldmakers to invest more efficiently and quickly in production.
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