Calloy USA Microdrill production line

The company has introduced its Calloy USA microdrill production line to the north American market. According to the company, the quality of the product line and its competitive pricing make it an attractive project. Located in Europe, the plant has been providing sophisticated products since 1928. For years, Calloy USA for the Swiss watch industry has been about microprecision.

Standard product size starts. 1mm(0.0039) to 3mm (0.118), in the hss-e-8% cobalt and 10% microgranular solid carbide, including the pilot point, 4-5-x D, 5-7 X D and 6-7 X D (high performance) series. Order the product within 2-3 weeks (10 pieces).

The Sec tool introduced the company’s new AM1 and AM2 polycrystalline diamond (PCD) drilling RIGS for composite manufacturing. It is reported that the new diamond cutting-edge technology to eliminate cutting fiber in the composite processing or layered problems, and make the company successfully developed the industry’s first three PCD groove geometry (AM1) used for composite drilling. AM1 and AM2 PCD are designed to provide the sharpest and most powerful cutting edges available now, using reliable PCD techniques. These techniques can be sharper than the PCD coating, and when the coating is applied, the package cuts the edge and produces a blunt effect. The additional advantages of new solid PCD include high cutting speed, long knife life, low friction, excellent thermal conductivity, multiple sharpening ability and high process reliability.

“In compound processing, sharp edges are very hard to cut in all materials,” says Scott Turner, the company’s marketing manager. If not cut, these fibers will eventually lead to wear and premature replacement of the material. In addition, sharper cutting tools have less pressure on materials, less stress, and less toughness.

In order to effectively utilize the “ordinary” composite material, the third flute on AM1 provides high level of stability, but also reduces vibration and improves roundness. Similarly, AM1’s domed tip applies a biangular geometric shape that reduces uncut fibers and reduces layering in composite applications. It is impossible to grind these highly complex geometries using conventional brazing or similar PCD techniques.

Micro tool coating points

Pfefferkorn argues that, in fact, the geometric characteristics of the micro-tool are not as precise as desired, “the radius of the cutting edge of the miniature end mill is already greater than we would expect from the chip load produced during cutting.”

In addition to working with researchers with experience in hot-wire CVD deposition, the team chose this deposition process because the thickness of the coating deposited by other CVD methods, such as plasma-based deposition processes, The multi-material is deposited on the tip, Pfefferkorn says, “Growing a sphere on a sharp cutting edge like a dog’s bones. I’m not saying that hot wire CVD is the only way to use it, The reason is because it does not produce this ‘dog bone effect’. ”

The coating is not only thinner. And must have good adhesion with the matrix, but also should be continuous and smooth, although the latter feature is difficult to quantify. “We are trying to eliminate the limitations of building suitable models for smoothness,” says Carpick. “So we can not know exactly how smooth the coating needs, and we think that a little bit rough may be useful because it may Helping to prevent the workpiece material from sticking to the tool.

Since the nanocrystalline diamond coating can be very thin, it can be adapted to the surface morphology of the substrate, including the grinding of the tool grinding and the cracks caused by the etching process. The micron grain coating can cover these surface defects. Pfefferkorn said, “micro-tools have been quite rough, we do not need to make them more rough.”

Processing of Micro tool coating

To the cobalt treatment, the need to selectively etching out the most appropriate amount of cobalt, and not too much to weaken itself is very thin micro-cutting tool In order to prevent the removal of too much drilling and affect the integrity of the tool, Weight ratio) must not exceed 6% to 8%. “We cut all the cobalt in the thin surface to prevent it from affecting the growth of the diamond,” says Pfefferkorn, “and we minimize the effect of tool integrity by controlling the depth of the etch.”

The paper points out that the research team at the University of Wisconsin-Madison conducted a seeding operation after completion of the etching: the use of ultrasonic treatment in acetone, the use of nano-diamond powder on the matrix deposition of diamond particles. The introduction of the grain played a role in positioning, where the diamond began to grow (ie nucleation). Nano-diamond powder agglomeration leads to uneven seeding and uneven growth of diamonds. Therefore, the researchers used ultrasonic cleaning in alcohol solutions to ensure that large grains were removed to achieve uniform seeding.

Then, using the hot-wire chemical vapor deposition system designed and fabricated by the research team, nano-grain and fine-grained diamond were grown on the tool. Carpick confirmed that the grain size of nanocrystalline diamond was 10 to 100 μm, Particle size greater than 100nm, less than 300nm). The deposition system comprises a deposition chamber in which the tungsten wire at a temperature of at least 1800 ° C is filled with a shielding gas (particularly methane diluted in hydrogen).

The thickness of the coating obtained by deposition is about 60 to 200 m. The average tool has a diamond coating thickness of 2μm or more, which is too thick for micro-tools because the radius of the cut edge of the uncoated micro-tool is often less than 1μm. “The thickness of the coating used for large-scale tools is not suitable for micro-tools, it will passivate the tool and thus greatly reduce its cutting performance,” Carpick said.

Find a better micro-tool coating

Since the coating of the cutting tool is beneficial to the processing of the macro size, there may be reason to deduce that the tool coating is also advantageous for small size machining. If the coating is properly applied and the coating thickness is thin enough to pass the microcrystalline edge, some researchers may agree with this view. However, these researchers have not yet finalized whether the micro-tool coating is conducive to processing, as well as the best way to coat.

In order to understand how to more effectively the micro-tool coating, some universities are carrying out relevant research. This paper is a study of the University, including the deposition of diamonds and other coatings on micro-tools, the selection of preferred coating methods, and the study of different workpiece materials on the coating tool response.

Application of an increasing number of diamond coatings

One of the challenges for diamond coatings is the adhesion of the coating to the tool surface. A team of researchers from the University of Wisconsin-Madison, the University of Pennsylvania and the Argonne National Laboratory has deposited a layer of transition on micro-end mills to enhance the adhesion of diamonds, And deionized water were tested on a 300 μm double-slot micro-end mill. According to Flank E. Pfefferkorn, assistant professor of mechanical engineering at the University of Wisconsin-Madison, one of the purposes of this test is to create a mechanical link between the cemented carbide substrate and the diamond coating.

Pfefferkorn and Robert W. Carpick, Associate Professor, Department of Mechanical Engineering and Applied Mechanics, University of Pennsylvania (who was dedicated to the study of diamond coatings at the University of Wisconsin-Madison) and his graduate students and partners in the paper titled “Diamond Micro Milling cutter: the ability to micro-size aluminum cutting “papers pointed out that the cobalt binder can enhance the toughness of the tool, but will weaken the diamond coating and the bonding strength between the matrix, and by limiting the formation of nuclei and inhibit the diamond Grow. “The main reason for removing the drill from the surface of the substrate is that it hinders the growth of the diamond,” Pfefferkorn said.

Milling of graphite materials

When cutting graphite material, its high abrasiveness will make the standard carbide cutting tool rapid wear, and wear the tool will not be able to accurately cut out the required complex geometric shape. When milling graphite, the tool path and milling method are not the most critical factors, and the type of milling cutter usually depends on the shape of the graphite electrode. As the diamond-coated cutter has excellent wear resistance, it is widely used in graphite milling. Diamond grown on a carbide tool base creates a wear-resistant coating that is extremely high in hardness and can significantly extend tool life. The life of the diamond-coated tool is 10-30 times longer than that of the uncoated carbide tool.

For example, when a complex graphite electrode of 152.4 mm square is machined with an uncoated carbide ball milling cutter with a diameter of 12.7 mm, the sharp edge and detail features of the milling cutter are usually about 4 hours after milling Began to peel off. And a diamond-coated cutter can be more than 98 hours of continuous milling, the cutting edge will not occur peeling off.

The sharpness of the cutting edge of the milling cutter is particularly high when machining certain graphite workpiece shapes (eg thin ribs), sharp geometric profiles and small size workpieces. In such processing, the use of 2-3μm thick diamond coating can extend the tool life and keep the edge sharp. Because of this relatively thin diamond coating cost is low, it is very suitable for the tool life requirements are not too high low-end processing. While the typical thickness of 18μm diamond coating is mainly used for high tool life requirements of high-end processing.

The use of thinner diamond coatings makes it impossible for moldmakers who produce smaller batches and want to reduce tool costs without sacrificing tool life in order to reduce costs. They can still play a real diamond-coated carbide cutting tool performance advantages while at the same time using thinner diamond coatings to meet their specific processing needs. Today’s diamond coating thickness range is roughly 2-25μm.

The optimum tool for a particular process should depend not only on the material being cut but also on the type of cutting used and the milling method used. By optimizing the tool, cutting speed, feedrate and machining programming skills, you can produce parts faster and better at lower processing costs.

High performance drill bit from Calloytool

The engineering company says its replacement t-a rig system can significantly reduce downtime compared to solid tools. The t-a drilling system has high performance insertion and application for making engine block, crankshaft, piston and suspension parts. The cost of using the t-a drilling system is 25-50% lower than other options on the market.

It is reported that in the case of t – a drill line, every time the operator insert bit, will have a perfect factory or drill point on the ground, without stopping, for regrinding operation need to change the tool offset. These alternate techniques are consistent each time, unlike the changes that are often encountered when using different mechanics to drill ground.

The allied forces provide the cast iron (-ci) geometry for its t-a drill, which is an ideal choice for automotive applications. With a lower rake Angle and a harder cutting edge to make it more elastic, (-ci) bit is a good choice made of cast iron and head. You can also use training techniques for other specific applications. The Allies developed custom configurations for tools, including a special shape end at the end of the crankshaft.

The innovative coating for the t-a rig includes the exclusive WD200 coating of the allied forces, which improves performance and extends the service life of the cutter. A variety of insertion levels applicable to automotive applications, including carbonized carbide, a wear-resistant carbonized carbon and carbohydrate, is a good choice for aluminum and other nonferrous metals.

Steel applications using the CAN2 t-a drill can use the C1 option, which is the same as the original t-a, providing better performance and longer tool life for automotive applications.

The company has expanded its SAF replacement headdrill production line, including 12XD bit. The SAF’s replaceable head drill reportedly allows for deep excavation at a lower cost, as SAF users can purchase only one drill to reach the size of 5.

It adopts the original radial saw tooth joint design, SAF bit, or cutting edge, which is designed for high precision and stable drilling. Polished flute ensures good chip evacuation.

According to the company, SAF’s nickel-plated fuselage has a longer life span than a conventional removable drill. Hard alloy matrix with patented hard alloy coating has excellent wear resistance on cutting edge. A rigid saw tooth coupling system is used to fix the replaceable carbide tip on the drill bit, improving the precision and repeatability of the drill.

Sumitomo provides a series of drills to improve the performance of various materials. SAFT – MTL type bit is excellent in steel application, while SAFT -c has a chamfer edge to eliminate fracture in cast iron application. SAFT – MEL machine superalloy, stainless steel and cast iron processing power.

In addition to the new 12XD, sumitomo’s SAF line also includes 3XD, 5XD and 8XD replaceable hard alloy bits.

Selection of Milling Cutters under Complicated Machining Conditions-Milling straight wall

Milling straight wall

The use of bovine nose mills is best when milling a flat area with flat ribs or straight walls. 4-6 blade of the nose and nose cutter is particularly good at the straight wall with the external shape or very open parts of the copy copy. The greater the number of blades, the greater the feedrate. However, the machining programmer still needs to minimize the surface contact of the tool with the workpiece and use a smaller radial width. When machining on a less rigid machine, it is advantageous to use a smaller diameter cutter because the small diameter milling cutter reduces contact with the surface of the workpiece.

The use of multi-edged nose nose cutter (including walking step and cutting depth) is the same as the ring cutter. They can be used to cut the hardened material with a cycloid tool path (or a new tool path that can control the knife’s knife angle). As mentioned earlier, the most important thing is to ensure that the cutter diameter is about 50% of the groove width, so that the milling cutter has enough moving space and to ensure that the knife angle does not increase and produce excessive cutting heat.

Precision drilling of silver and diamond

The company‘s general drilling line includes precision drilling for precision drilling of silver and diamond. These decompression drills provide versatility and reliability.

The precision drill A56 is an inch diameter round handle suitable for an inch – in – holder bit. Regular flutes and total length allow minimum adjustment of drilling machine. Suitable for low – to moderate tensile strength of various materials.

The precision twist drill A57 features three planes with a diameter of an inch and a corrected anti-skid.

Precision twist drill A56CO is produced by high quality cobalt steel for improving hardness, abrasion resistance and thermal resistance. It is characterized by a 118 a self-centering locations, accurate positioning and easier to insert A56CO is an ideal material of tensile strength of high strength, can produce high cutting temperature, such as high alloy steel, iron castings, stainless steel and other hard processing material.

WE cutting tool company carbide tool set of the introduction of the new “rapid drilling” geometry, according to the report, which provides unprecedented cutting speed and tool life than ever, including grey cast iron, nodular cast iron and forging steel, these are the popularity of automotive engine and chassis components material. With a new round radius design, it has nothing to do with the Angle of the drill, but it has nothing to do with the diameter. These verified designs solve the challenging, high-yielding drilling applications. Tool selection includes standard drill and endmill procedures for all materials groups; Special tools include step drilling, coring, reamer, taper drill, tapered reamer and assembly tools (drilling and milling), and provide superior cost/performance ratio.

In decades of experience and engineering, Calloy tools provide a single tool for drilling operations, providing solutions for project management of all solid carbide tools. The precision and precision are ensured by industry-leading innovative design, ultra-modern CNC grinder and strict iso 9001 quality system.

Calloy’s sales and application engineers can assist with the selection and design of tools to meet specific application requirements with the best geometry, the latest carbonization grade and advanced coatings. Fast and reliable delivery time, with decades of experience in the design and manufacture of precision hole tools.

Complicated machining process-Milling small parts

Milling small parts

A circular milling cutter is the best choice for milling small parts (such as helical milling and milling ribs, or when the cutter diameter is close to the workpiece radius). The solid ring shape of this cutter can produce a chip thinning effect that allows it to be milled at a higher feed rate. In addition, the radius of the milling cutter is smaller than that of the conventional ball end mill, so it can increase the walking step, while still maintaining the flatness of the machined surface without the usual occurrence of the ball milling cutter Large knife marks.

The ring cutter is ideal for helical milling and milling ribs because the tool will inevitably produce more contact with the machined surface, while the use of double-edged circular milling cutters minimizes contact with the surface of the workpiece, Thereby reducing cutting heat and tool deformation. In these two machining, the circular milling cutter is usually closed in the cutting state, so the maximum radial walking step should be 25% of the diameter of the milling cutter, and each time the maximum Z direction of the knife should be cut 2% of diameter. In the helical milling hole, when the cutter is cut into the workpiece with the helical cutter rail, the spiral cutting angle is 2 ° – 3 ° until the Z direction of the cutter diameter is 2%.

If the ring cutter is open in the open state (such as milling the workpiece corner or cleaning the workpiece characteristics), the radial walking step depends on the hardness of the workpiece material. When the hardness of the workpiece is HRC30-50, the maximum radial walking step should be 5% of the diameter of the cutter; when the material hardness is higher than HRC50, the maximum radial walking step and the maximum Z The depth of cut is 2% of the diameter of the cutter.

Freze Kesicilerinin Seçimi – Komple işleme işlemi

Makine sertliği, kullanılabilen aracın boyutunu belirlemeye de yardımcı olur. Örneğin, 40 konik makinede kesim yaparken, freze bıçağı çapı normal olarak <12.7 mm olmalıdır. Daha büyük çaplı frezeleme aletleri, makinenin dayanma kabiliyetini aşan daha büyük kesme kuvveti üretebilir; bu da çarpma, deformasyon, yüzey bitirme bozulması ve takım ömrünün kısalmasına neden olur.

Buna ek olarak, parçanın en küçük çapının öğütme frezesinin 1/2’inin kullanılması, küçük bir bıçak bıçağı açısı tutabilir ve direksiyon sırasında takım artmaz. Örneğin, iş parçası işleme programı% 10’luk bir yürüme adımı, daha sonra bıçak açısı 37 °’yi kullanır. Eski, geleneksel alet yolunu kullanırsanız, yön değiştirdiğinizde kesici açısını 127 ° ‘ye değiştirecektir. Ve yeni yüksek hızlı takım yolunun kullanılması, sesin köşesinde kesici ve düz çizgi kesme işlemi farklı değil. Bir kesiciye tüm kesme işlemlerinde aynı ses verilirse, büyük bir termal şoka ve mekanik darbeye maruz kalmadığına işaret eder. Kesici her turda çığlık atıyorsa veya bir köşede kesilirse, bıçağın açısını azaltmak için kesicinin boyutunu azaltmanın gerekli olabileceğini gösterir. Kesimden çıkan ses aynı kalırsa, bıçağın açısı daima sabit olduğu için, kesicinin kesme basıncının üniform olduğu ve iş parçasının geometrisinin değişmesi ile yukarı ve aşağı dalgalanmadığını gösterir.