热熔钻操作说明.doc

热熔钻操作说明一、手动进给操作步骤 1. 正确选择热熔钻（孔径和类型） 2. 确保设备的功率和转速3. 正确将夹头装入刀柄 4. 将热熔钻钻头装入夹头并锁紧 5. 将刀柄接入钻床 6. 将加工工件紧固在工作台上 7. 确保工件和刀具之间的合适运行范围 8. 正确选择转速 9. 正确选择钻孔深度 10. 加少量润滑油于刀具上 11. 下压手柄，保持规则匀速的进给速度，不可停顿 12. 当钻头底部到达工件表面，迅速放松手柄 13. 注意观察钻孔时间和钻头颜色 14. 注意调节转速和进给速度。（步骤8，11，温度过高：降低转速或提高进给速度，或二者） 注意：平口型热熔钻的操作 l 将会产生一小条钻屑，请作好防护。 l 在进行平口型钻头操作过程中，只需在切削开始时，进行瞬间加速进给。瞬间加速进给将会大大延长刀具使用寿命。 l 通过观察钻屑的长度和形状，可以确定操作的准确性。钻屑长而细，错误钻屑短而粗，正确正确进行瞬间加速，将会延长刀具使用寿命二、 热熔钻使用注意事项1. 工件材料：热熔钻适用于加工工件孔径1.8-32mm，壁厚0.512.5mm的多种金属材料，如低碳钢、不锈钢、钛、铝、铜、紫铜、黄铜(Zn含量低于40)、铝合金(si含量低于0.5%)等。如果材料越厚、越硬，热熔钻头使用寿命越短。2. 热熔钻在工作时，瞬间产生600 C以上的高温，特制的润滑膏能延长钻头的使用寿命，改善圆柱体内表面的质量，产生清洁的和令人满意的边缘形状。建议普通碳钢每钻5个孔，加少许润滑膏于刀具上；不锈钢工件，每钻一个孔，需添加润滑膏；材质越厚、越硬，使用频率越高。可以手工涂抹润滑膏，也可以自动喷淋润滑油；因一般油脂无法达到高温，故需使用特别开发的油脂。3. 热熔钻的刀柄和夹头，如果没有专用散热器，可使用压缩空气降温。4. 只要达到合适的转速和功率的各种钻床、铣床和加工中心都适合于热熔钻；钻床要根据热熔钻使用参数表，选择相应的功率和转速；与传统的加工工艺相比，热熔钻加工需要更高的转速，孔径的大小、材料的厚度以及材料本身的不同都影响到转速的确定；需要的转速范围从1,000到3,500 RPM；需要的功率从1.5KW到3.5KW。5. 预制孔：通过预先钻削一个小的起始孔能避免工件变形。预制孔可以减少轴向力，也可以减小圆柱体的高度，还可以在圆柱体的最下端部产生一个光滑的边缘，还可以避免薄壁（小于1.5毫米）工件的弯曲变形。6. 带槽钻尖型热熔钻头（头部带切削刃），推荐用于加工表面涂层的工件材料。因为这种钻尖有助于在钻削加工开始时去除覆盖在工件表面上如油漆、镀锌等任何妨碍钻孔的覆盖层。这个切削刃用来还有助于防止薄壁工件在钻头向下的压力作用下可能产生的变形。带有切削刃的钻头使钻孔变得很轻松，由于切削刃的存在，可适当减小钻孔时的轴向力，适用于：因工件厚度较薄而在钻孔时容易弯曲；硬度较小的材料。7. 在攻丝时，选用攻丝油。可以使用普通切削丝锥，但推荐采用挤压丝锥，这种螺纹不是通过切削而是通过挤压形成的，因此具有较高的拉伸强度和扭矩值。8. 热熔钻的维护保养：热熔钻使用一段时期后，表面会有磨损，刀体上会附和一些热熔膏或工件杂质，为确保加工工件的准确，提高热熔钻的使用寿命，可将热熔钻夹在车床或铣床夹头上，用研磨膏修磨即可，切忌注意安全。四、影响热熔钻寿命的因素1. 尽管热熔钻机械强度仍可保持在高温下工作，但材料对于热应力仍然敏感，所以必须避免温度急速升高或降低，必要时加风洽，使钻头保持黑红。为了防止主轴温度过高，建议使用特殊散热式夹具。2. 热熔钻不耐震，故不能以尖端快速接触材料，而稳定的加压非常重要。在穿透材料时，需避免挠出的效应发生，压力必须减少很多，否则会造成力量不相称，钨材在此种情况下会产生不均匀疲劳效应。3. 钻床主轴不稳定会造成钻头伤害，不要再钻不完整的孔，因孔已收缩。同一孔因故未完成，不可再行钻孔，必须放弃。 4. 经常润滑钻头自然对工作寿命有利，使用钻石挫刀和砂纸清洁钻头效果很好。 5. 在材料厚时，不妨先做一个导引孔或使用绞式钻头，如此可减少钻头压力。 6. 使用平口型钻头避免铁屑粘在边缘，必需用风吹开及减速50%70%RPM 附件一：不同材料厚度热熔钻使用参数表1mm壁厚材料1.5mm壁厚材料2mm壁厚材料2.5mm壁厚材料螺牙孔径热熔钻孔径转速Rpm功率kW进给mm/min转速Rpm功率kW进给mm/min转速Rpm功率kW进给mm/min转速Rpm功率kW进给mm/minM公制粗牙M x 公制细牙M2 1.834000.510034000.58032000.58032000.680M2.5 2.334000.510034000.58032000.58032000.680M3 2.732000.612032000.610030000.610030000.6100M4 3.730000.712028000.712026000.712026000.7120M4x0.5 3.830000.712028000.712026000.712026000.7120M5 4.528000.815028000.815025000.815025000.8150M5x0.5 4.828000.815028000.815025000.815025000.8150M6 5.328001150260011502400115024001150M6x0.75 5.628001150260011502400115024001150M6x0.5 5.828001150260011502400115024001150M8 7.328001.315024001.315022001.315022001.3150M8x1 7.528001.315024001.315022001.315022001.3150M8x0.75 7.628001.315024001.315022001.315022001.3150M10 9.224001.515022001.515020001.515020001.5150M10x1.25 9.324001.515022001.515020001.515020001.5150M10x1 9.524001.515022001.515020001.515020001.5150M12 10.922001.715020001.715018001.715018001.7150M12x1.5 11.222001.715020001.715018001.715018001.7150M12x1 11.522001.715020001.715018001.715018001.7150M14 13180021501600215016002150M14x1.5 13.2180021501600215016002150M16 14.816002.215014002.215014002.2150M16x1.5 15.216002.215014002.215014002.2150M18 16.716002.515014002.515014002.5150M18x1.5 17.316002.515014002.515014002.5150M18x1 17.516002.515014002.515014002.5150M20 18.716002.715012002.715012002.7150M20x1.5 19.216002.715012002.715012002.7150M20x1 19.516002.715012002.715012002.7150G1/8 9.222001.515020001.515020001.5150G1/4 12.4180021501600215016002150G3/8 15.916002.215014002.215014002.2150G1/2 19.9140031501200315012003150G3/4 25.414003.515010003.515010003.51503mm壁厚材料3.5mm壁厚材料4mm壁厚材料4.5mm壁厚材料螺牙孔径热熔钻孔径转速Rpm功率kW进给mm/min转速Rpm功率kW进给mm/min转速Rpm功率kW进给mm/min转速Rpm功率kW进给mm/minM公制粗牙M x 公制细牙M2 1.830000.680M2.5 2.330000.680M3 2.730000.8100M4 3.726000.81202400110024001.3100M4x0.5 3.826000.81202400110024001.3100M5 4.5240011202400112022001.310022001.5100M5x0.5 4.8240011202400112022001.310022001.5100M6 5.32200115022001.315020001.312020001.5120M6x0.75 5.62200115022001.315020001.312020001.5120M6x0.5 5.82200115022001.315020001.312020001.5120M8 7.322001.315020001.315020001.512018002120M8x1 7.522001.315020001.315020001.512018002120M8x0.75 7.622001.315020001.315020001.512018002120M10 9.220001.515020001.51501800212018002120M10x1.25 9.320001.515020001.51501800212018002120M10x1 9.520001.515020001.51501800212018002120M12 10.918001.715018001.71501800212016002120M12x1.5 11.218001.715018001.71501800212016002120M12x1 11.518001.715018001.71501800212016002120M14 13160021501600215016002.512016002.5120M14x1.5 13.2160021501600215016002.512016002.5120M16 14.814002.215014002.212014002.512014002.5120M16x1.5 15.214002.215014002.212014002.512014002.5120M18 16.714002.515014002.51201400312014003120M18x1.5 17.314002.515014002.51201400312014003120M18x1 17.514002.515014002.51201400312014003120M20 18.712002.715012002.71201200312012003150M20x1.5 19.212002.715012002.71201200312012003150M20x1 19.512002.715012002.71201200312012003150G1/8 9.220001.515020001.51501800212018002120G1/4 12.4160021501600215016002.512014002.5120G3/8 15.914002.215014002.212014002.512014002.5120G1/2 19.912003150120031201200312012003120G3/4 25.410003.515010003.512010003.515010003.51505mm壁厚材料5.5mm壁厚材料6mm壁厚材料6.5mm壁厚材料螺牙孔径热熔钻孔径转速Rpm功率kW进给mm/min转速Rpm功率kW进给mm/min转速Rpm功率kW进给mm/min转速Rpm功率kW进给mm/minM公制粗牙M x 公制细牙M2 1.8M2.5 2.3M3 2.7M4 3.7M4x0.5 3.8M5 4.5M5x0.5 4.8M6 5.318002100M6x0.75 5.618002100M6x0.5 5.818002100M8 7.318002.512016002.510016002.5100M8x1 7.518002.512016002.510016002.5100M8x0.75 7.618002.512016002.510016002.5100M10 9.216002.512016002.51001400310014003100M10x1.25 9.316002.512016002.51001400310014003100M10x1 9.516002.512016002.51001400310014003100M12 10.916003120140031001400310014003100M12x1.5 11.216003120140031001400310014003100M12x1 11.516003120140031001400310014003100M14 1314003120140031001400310012003100M14x1.5 13.214003120140031001400310012003100M16 14.814003120140031001200310012003100M16x1.5 15.214003120140031001200310012003100M18 16.7140031201200312012003.512012003.5100M18x1.5 17.3140031201200312012003.512012003.5100M18x1 17.5140031201200312012003.512012003.5100M20 18.7120031201000312010003.512010003.5120M20x1.5 19.2120031201000312010003.512010003.5120M20x1 19.5120031201000312010003.512010003.5120G1/8 9.216002.512016002.51001400310014003100G1/4 12.414003120140031001400310012003100G3/8 15.9120031201200310012003.510012003.5100G1/2 19.9100031201000312010003.512010003.5120G3/4 25.49003.51209003.5120900412090041207mm壁厚材料7.5mm壁厚材料8mm壁厚材料8.5mm壁厚材料螺牙孔径热熔钻孔径转速Rpm功率kW进给mm/min转速Rpm功率kW进给mm/min转速Rpm功率kW进给mm/min转速Rpm功率kW进给mm/minM公制粗牙M x 公制细牙M2 1.8M2.5 2.3M3 2.7M4 3.7M4x0.5 3.8M5 4.5M5x0.5 4.8M6 5.3M6x0.75 5.6M6x0.5 5.8M8 7.3M8x1 7.5M8x0.75 7.6M10 9.2M10x1.25 9.3M10x1 9.5M12 10.91200310012003100M12x1.5 11.21200310012003100M12x1 11.51200310012003100M14 131200310012003100M14x1.5 13.21200310012003100M16 14.8100031001000310010003.510010003.5100M16x1.5 15.2100031001000310010003.510010003.5100M18 16.7100041001000410010004.510010004.5100M18x1.5 17.3100041001000410010004.510010004.5100M18x1 17.5100041001000410010004.510010004.5100M20 18.7900410090041009005.51009005.5100M20x1.5 19.2900410090041009005.51009005.5100M20x1 19.5900410090041009005.51009005.5100G1/8 9.2G1/4 12.41200310012003100G3/8 15.910003.510010003.51001000410010004100G1/2 19.9900410090041009005.51009005.5100G3/4 25.49004.51009004.51009005.51009005.51009mm壁厚材料9.5mm壁厚材料10mm壁厚材料螺牙孔径热熔钻孔径转速Rpm功率kW进给mm/min转速Rpm功率kW进给mm/min转速Rpm功率kW进给mm/minM公制粗牙M x 公制细牙M2 1.8M2.5 2.3M3 2.7M4 3.7M4x0.5 3.8M5 4.5M5x0.5 4.8M6 5.3M6x0.75 5.6M6x0.5 5.8M8 7.3M8x1 7.5M8x0.75 7.6M10 9.2M10x1.25 9.3M10x1 9.5M12 10.9M12x1.5 11.2M12x1 11.5M14 13M14x1.5 13.2M16 14.8M16x1.5 15.2M18 16.71000510010005100M18x1.5 17.31000510010005100M18x1 17.51000510010005100M20 18.7900610090061009006100M20x1.5 19.2900610090061009006100M20x1 19.5900610090061009006100G1/8 9.2G1/4 12.4G3/8 15.910004.5100G1/2 19.9900610090061009006100G3/4 25.4900610090061009006100重要提示：以上表格中的参数是针对低碳钢；钻不锈钢时，螺牙孔径 M6 或以上的，建议热熔钻直径要增大 0.1mm （例如：M6螺牙时用5.5mm替换5.4mm，M8螺牙时用7.4mm替换7.3mm），并调低钻机转速 15%；钻铝或其他有色金属，要调高钻机转速 50%。附件二：使用范例Mildsteel Fe 360（软钢）=2mm螺牙孔径 热熔钻孔径 (mm) 钻机转速 （RPM）钻机功率 （KW）钻孔所需时间（秒）攻牙机转速（RPM） M2 1.832000.521600M3 2.730000.621350M4 3.726000.721000M5 4.525000.82800M6 5.4240012650M8 7.322001.32500M10 9.220001.53400M12 10.918001.73330M16 14.814002.24250M20 18.712002.75200G1/8 9.220001.53400G1/4 12.4160023360G3/8 15.914002.34300G1/2 19.9120035270G3/4 25.410003.56200重要提示：1. 以上表格中的参数是针对2mm厚低碳钢；2. 对更厚的材料，每增加1mm，加工时间增加1秒钟；3. 钻不锈钢时，螺牙孔径 M6 或以上的，热熔钻直径要大 0.1mm，并调低钻机转速 15%；4. 钻铝或其他有色金属，要调高钻机转速 50%。附件三：热熔钻最大穿透厚度Thread螺纹 热熔钻直径Max. material thickness最大穿透厚度Collet夹头Total length working part工作面总长度Short短型Short/Flat短/平型Long长型Long/Flat长/平型Short短型Long长型M21.81.61.82.23.265.87.8M2.52.31.61.92.33.566.18.1M32.71.722.43.766.78.7M43.71.82.22.64.268.110.3M4 x 0.53.81.82.22.64.268.210.5M54.51.92.42.74.669.211.8M5 x 0.54.81.92.42.74.769.612.4M65.322.52.95610.313.5M6 x 0.755.622.52.95610.814.2M6 x 0.55.822.635.2611.214.7M87.32.22.93.35.9813.518.1M8x 17.52.32.93.4681418.7M8 x 0.757.62.32.93.46814.118.8M109.22.63.23.76.61016.822.5M10 x 1.259.32.63.33.76.7101722.8M10 x 19.52.63.33.86.71017.323.2M1210.92.83.547.21219.826.4M12 x 1.511.22.83.64.17.31220.327.1M12 x 111.52.93.64.27.31220.827.8M141333.94.57.91423.531.3M14 x 1.513.23.144.681423.831.6M1614.83.34.24.88.51626.935.4M16 x 1.515.23.44.34.98.71627.636.3M1816.73.54.65.29.21830.439.7M18 x 117.53.74.85.69.51831.941.5M 2018.73.855.79.91834.144.3M 20 x 1.519.23.95.15.8101835.145.5M 20 x 119.53.95.25.8101835.646.2G1/167.32.32.93.35.9813.518.1G1/89.22.63.23.76.61016.822.5G1/412.42.93.84.37.81222.429.8G3/815.93.44.558.91628.937.9G1/219.945.25.9101836.347G3/425.44.86.2710.42046.459.