The most commonly used processing methods in high-speed machining is a high-speed milling instead of EDM with a high-speed milling mold mold has the following advantages.
(1) processing of good quality
The mold of traditional EDM processing, in the local high-temperature discharge ablation process on the workpiece surface, the surface of the workpiece material's physical - mechanical properties will be some damage, often produce fine cracks in the surface of the cavity, it is difficult to guarantee the quality of the workpiece . High speed milling cutting speeds about 10 times higher than conventional milling speed processing of parts, rough margin had a chance to fully deformed instantly cut away from the workpiece, the workpiece surface residual stress is very small. The same time, the process of high-speed milling machine spindle high speed (8000r/min ~ rate of 100000r/min) machine - fixture - workpiece - tool "technology system excitation frequency is much higher than the natural frequency range, part process smooth impact. Therefore, high machining accuracy and surface quality. High-speed milling the mold cavity, the surface quality can reach the level of grinding, so eliminating the need for subsequent grinding process.
(2) high production efficiency
EDM rely on discharge ablation of micro-cutting, the process is very slow, at the same time, the surface roughness of the mold cavity is less than the mold, often need to conduct time-consuming manual grinding after EDM and polishing the mold, the production efficiency of this process is very low. Processing center or high-speed milling machine, cutting mold, the efficiency of the process itself several times higher than the EDM. Can complete the cavity of the rough, finishing and other parts of the mold machining in the workpiece in a single setup, namely the so-called "one-off" technology (One Pass, Machining). In addition, the technology does not
Do electrode and the subsequent hand-grinding and polishing, easy to implement process automation. The high-speed machining technology enables mold development speed greatly improved.
(3) processing the complex shape of the hard parts and thin-walled parts
We can see by the high-speed cutting mechanism, high-speed milling cutting force is greatly reduced, the cutting process becomes easier.
The high-speed machining hardened steel processing material hardness up to 60HRC above, without cutting fluid, the so-called hard cutting (Hard Machining) and dry cutting (Dry Machining). More prominent, small, horizontal cutting force in high-speed milling and processing complex in the mold cavity thin ribs and thin-walled (wall thickness less than 1mm) is extremely favorable. Of course, high speed milling of mold there are also some limitations. When the workpiece material hardness greater than 60HRC, and has a narrow and deep cavity, and the very hour of chamfers and fillets, high-speed milling is very difficult, while the organic combination of high-speed milling and EDM can reach more good economic results.
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