干湿加工应用参数比较(all)ch.doc

典型干式加工机架 材料:St37K(DIN 174 FL 50x40) 加工设备:TRAUB TNA 300速度:505,000 rpm冷却润滑剂 :以前 (wet):乳化液现在 (MQL)准干式润滑剂湿加工干式加工n切削速度FeedCutting speedFeedToolsVc m/minf mm/revToolsVc m/minfn mm/rev1st setup1st setup车刀1800,18External turning tool2000,20麻花钻 19600,10Twist drill 192000,06车刀2000,10External turning tool2200,10镗刀1500,08Internal turning tool1800,10攻丝刀651,50Threading tool1001,50内开槽刀具600,06Internal recessing1300,08tool合计时间:306minTotal time: 157 min Time saved: 37 % 准干式加工典型应用盖板Material:GG 20RD40Machine:Heckert BAZ CWK400D Speed range:5015,000 rpm冷却润滑剂:原来 (wet)乳化液现在 (MQL)准干式润滑剂Wet machiningDry machiningfCutting speedFeed speedCutting speedFeed speedToolsVC m/minV mm/minToolsVC m/minVf mm/minStep drill100588Solid carbide step7361 12.5 15drill 5.8 10; FireCounterbore5090Solid carbide step73441 5.8 10drill 5.8; FireSolid carbide drill100327Solid carbide step73505 5.8drill 4.6; FireSolid carbide drill100270Solid carbide step drill73505 4.5 4.8. 12.5; FireSolid carbide drill100260Solid carbide step drill73517 4.6 4.5; FireSolid carbide drill100270Tap M14x1.5 TiN301023 4.8Solid carbide drill100328Solid carbide step73441 5.8drill 5.8; FireSolid carbide drill100549Solid carbide reamer8,454 12.5 6 G7 TiAlNTap M14x1.5; HSS151024Countersink 6.573447HSS drill 12.3100463 6 drilled out to G7 tolerance on special machineTotal time:524 minTotal time:148 min Time saved: 67 % 准干式加工典型应用垫板Material:GG 20RD40Machine:Heckert BAZ CWK400D Speed range:5015,000 rpm冷却润滑剂:原来 (wet)乳化液现在 (MQL)准干式润滑剂Wet machiningDry machiningfCutting speedFeed speedCutting speedFeed speedToolsVC m/minV mm/minToolsVC m/minVf mm/minSC drill 3.280145SC step drill73598 2.8, FireDrill 2.53528SC reamer18210 3 H7 TiAlNTap M3 TiAlN30142SC step drill70562 2.5, FireDrill 2.73530SC countersink 3,473684SC step drill735813.2, FireEnd mill 311047 3 drilled out to H7 tolerance on special machineTap M3 TiNSC step drill 3.4, Fire3012615921888Total time:312 minTotal time:130 min Time saved: 53 % 准干式加工典型应用机架Material:16MnCr5 1.7131 (DIN 1017 FL40x30) Machine:Heckert BAZ CWK400DSpeed range:5015,000 rpm冷却润滑剂:原来 (wet)乳化液现在 (MQL)准干式润滑剂Wet machiningDry machiningfCutting speedFeed speedCutting speedFeed speedToolsVC m/minV mm/minToolsVC m/minVf mm/minNC spotting drill 107080NC spotting drill 1080250SC twist drill 463100SC twist drill 490760SC twist drill 9,877450SC twist drill 9,877860Countersink for core2430Countersink for core47250M14x1,5M14x1,5Countersink for core2080Countersink for core46280M12x1,5M12x1,5Step drill4330Step drill72180 23 / 12,5 23 / 12,5SC twist drill 9,080450SC twist drill 9,080665Countersink for core2325Countersink for core70300M12x1,0M12x1,0Countersink 6/30840Countersink 6/3038225Tap M12x111300Thread miller87200M12x1.5; pitch 1Tap M14x1,519300Thread miller87240M14x1.5; pitch 2Tap M12x1,517300Thread miller87240M12x1.5; pitch 2Production on 3 machine toolsProduction on a machining centermade possible by the use of MQL toolsTotal time: 1542 minTotal time: 636 min Time saved: 58 % 准干式加工典型应用联接法兰盘Material:X10 CrNiS 18 9 1.4305(DIN 668 RD30)Machine:TRAUB TNA 300Speed range:505,000 rqm冷却润滑剂:原来 (wet)乳化液现在 (MQL)准干式润滑剂Wet machiningDry machiningCutting speedFeed fn mm/revCutting speedFeed fn mm/revToolsVC m/minFeed speedVf mm/minToolsVC m/minFeed speedVf mm/minTurning tool2200,20Turning 282500,25Twist drill 19150,14Disposable drill 191600,06Centering drill190,12Drilling 8.7600,08Twist drill 8100,12Drilling 10600,08Flat drill 18340,10Internal turning2500,10Flat drill 10130,12Thread chasing901,50M22x1.5Internal turning tool1520,12Groove milling38400Internal turning tool2070,08Thread551,50Recess500,06Groove milling1970,00Fewer machining operationsthanks to modified toolsTotal time:500 minTotal time:204 min Time saved: 59 % 准干式加工典型应用盘件Material:AlCuMgPbF38 (DIN 1770 Fl 80x15) Machine:TRAUB TNA 300Speed range:505,000 rpm冷却润滑剂:原来 (wet)乳化液现在 (MQL)准干式润滑剂Wet machiningDry machiningnCutting speedFeedCutting speedFeedToolsVc m/minf mm/revToolsVc m/minfn mm/rev1st setup1st setupT Max drill 25640,12T Max drill 242000,25External rough turning4400,15External rough turning8000,25External finish turning4850,08External finish turning8550,25Internal turning 26H7900,08Internal turning 26H73000,25Chamfer 1x45710,04Chamfer 1x452000,15Total time:245 minTotal time:045 min Time saved: 73 % 准干式加工典型应用泵主轴Material:X35CrMo17 1.4122(DIN 1013 RD 22) Machine:new: Brother TC 227Speed range:010,000 rpm冷却润滑剂:原来 (wet)乳化液现在 (MQL)准干式润滑剂Wet machiningDry machiningCutting speedFeed speedToolsV m/minV mm/minCutting speedFeed speedToolsV m/minV mm/minSolid carbide miller18,830Solid carbide miller65207 3, coatedDeburringmanualMiller 350742Universal milling machineTotal time:139 minTotal time:030 mincfcf Time saved: 70 % 准干式加工典型应用阀体Material:9SMnPb28K(DIN 174 Fl 40x25) Machine:TRAUB TNA 300Speed range:05,000 rpm冷却润滑剂:原来 (wet)乳化液现在 (MQL) 准干式润滑剂Wet machiningDry machiningnCutting speedFeedCutting speedFeed fn mm/revToolsVC m/minf mm/revToolsVC m/minFeed speedVf mm/min1st setup1st setupPredrilling500,20Facing2800,25Predrilling500,20T Max drill 191700,20Facing4700,08Undercut1500,12Rough turning1200,06Fit 20H9 turned2000,10Inside diameterThread M22x1,5turning1200,06milled4000 min 1500Thread cuttingM22x1,5101,50Total time:318 minTotal time:148 min Time saved: 45 % 准干式加工典型应用法兰块Material:Al Mg Cu PbF38Machine:DMG Twin 65Speed range:05,000 rpm冷却润滑剂:原来 (wet)乳化液现在 (MQL)准干式润滑剂Wet machiningDry machiningCutting speedFeed fn mm/revCutting speedFeed fn mm/revToolsVC m/minFeed speedVf mm/minToolsVC m/minFeed speedVf mm/minRoughing2500,30Facing, roughing2750,20Rough drilling500,12Rough drilling1250,20External finishing2300,10Centering (2x)225300Drilling (2x)32120Drilling 2,4 (2x)105280Tapping M3 (2x)50,50Centering (2x)/180 220950deburringInternal finishing950,08Drilling 4.8 (2x)180250Recessing470,05External finishing2750,15Tapping M3 (2x)40,502nd setupInternal finishing950,15 12 E9Rough countersinking600,10Recessing500,10Boring1650,05Facing, chamfering3450,15Centering (7x)70125Centering, deburring160 220980Drilling 4.8 (2x)53175Milling135540Drilling 2H9 (2x)25120Counterboring 8250250Drilling 2.5 (5x)32120Drilling 2.4 (5x)90240Tapping M3 (5x)30,50Tapping M3 (5x)40,50Counterboring5080Drilling 2H9 (2x)100300Rough countersinking500,15 24Completed in 2 setups of blanks.BoringParting2001200,120,12Total time:85 minTotal time:3,7 min Time saved: 56,5 % 准干式加工典型应用导向杆Material:AlCuMgPb F38 (DIN 1798 RD14) Machine:TRAUB TNA 300Speed range:05,000 rpm冷却润滑剂:原来 (wet)乳化液现在 (MQL)准干式润滑剂Wet machiningDry machiningnCutting speedFeedCutting speedFeedCentering50,10Centering200,20Finishing 12 f8830,10Finishing 12 f81800,06Deburring 3300,10Deburring 3600,10Drill 6.8120,10Drill 6.8600,10Drill 9150,10Drill 9401,50ToolsVc m/minf mm/revToolsVc m/minfn mm/rev1st setup1st setupThreads1501,25Threads4000,082nd setup2nd setupCentering570,10Centering1800,12Drilling 4.0310,10Drilling 4.01800,12Turning970,10Turning2000,12Thread chasing678 strokesThread chasing908 strokesM14x1.5 threadM14x1.5 threadDeburring970,12Deburring2000,12Total time:421 minTotal time:208 min Time saved: 49 % 准干式加工典型应用活塞Material:AlMgSi1 (DIN 1798 RD 40) Machine:TRAUB TNA 300Speed range:05,000 rpm冷却润滑剂:原来 (wet)乳化液现在 (MQL)准干式润滑剂Wet machiningDry machiningnCutting speedFeedCutting speedFeedToolsVc m/minf mm/revToolsVc m/minfn mm/revExternal turning toolCentering drill1st setup1507,50,100,08External turning toolCentering drill1st setup1507,50,100,08External turning tool3150,25External turning tool4750,25External turning tool3450,12External turning tool5400,15Ext. recessing tool1500,08Ext. recessing tool2400,30Ext. recessing tool1500,08Ext. recessing tool2250,20Ext. recessing tool2200,10Ext. recessing tool2600,08Ext. recessing tool1500,10Ext. recessing tool4000,03Twist drill 4,0150,08Twist drill 4.0150,08Twist drill 2,5100,08Twist drill 2.5100,08Tap M3External turning toolCentering drill1,52nd setup31511,50,500,120,10Tap M3External turning toolCentering drill1,52nd setup31511,50,500,120,10Total time:317 minTotal time:230 min Time saved: 24 % 准干式加工典型应用Flange AZ7 0108MGEFLA 001Material:AlCuMgPbF38 (DIN 1799 RD120) Machine:TRAUB TNA 300Speed range:05,000 rpm冷却润滑剂:原来 (wet)乳化液现在 (MQL)准干式润滑剂Wet machiningDry machiningnCutting speedFeedCutting speedFeedToolsVc m/minf mm/revToolsVc m/minfn mm/revTwist drill 17600,15Disposable drill 172830,25External turning tool7500,25External rough turning6000,30Internal turning tool1600,20Shaping pass2600,30Face recessing1200,08Internal finish turning2800,06External turning tool5650,20External finish turning6500,22External turning tool5650,12Internal turning tool1250,12Fewer machining operations due to modified toolsTotal time:452 minTotal time:053 min Time saved: 82 % 准干式加工典型应用工作活塞Material:16 Mn Cr 5Machine:DMG Twin 65Speed range:05,000 rpm冷却润滑剂:原来 (wet)乳化液现在 (MQL)准干式润滑剂Wet machiningDry machiningCutting speedFeed fn mm/revCutting speedFeed fn mm/revToolsVC m/minFeed speedVf mm/minToolsVC m/minFeed speedVf mm/minFacing / roughingFinishing800,10Centering120,05Recessing950,10Drilling 6.2/5.5400,07Rough milling701200,18100RoughingFacing1602000,300,12Milling4580Boring1350,05Profile milling3080Tap M6x0.5L150,50DeburringParting40400650,10MillingProfile millingMillingFinish milling Radius cutting Deburring Finishing Centering Recessing Rough milling Finish turning115120100125100959020929525090072048075040010000,230,030,103800,10Total time:600 minTotal time:350 min Time saved: 41,7 % 准干式加工典型应用连接法兰Material:AlMgSiPb F28 (DIN 1796 4Kt 50) Machine:TRAUB TNA 300Speed range:05,000 rpm冷却润滑剂:原来 (wet)乳化液现在 (MQL)准干式润滑剂Wet machiningDry machiningnCutting speedFeedCutting speedFeed2nd setup2nd setupExternal turning tool2200,08External turning tool3000,08Internal turning tool2651,50Internal turning tool2651,50Internal recessing750,06Internal recessing750,06ToolsVc m/minf mm/revToolsVc m/minfn mm/rev1st setup1st setupExternal turning tool2100,12External turning tool3000,20Disposable drill1130,15Disposable drill1650,06External turning tool2300,10External turning tool3150,10Internal turning tool2050,12Internal turning tool2350,10Threading tool492,30Threading tool1401,50Internal turning tool2050,15Internal turning tool2350,08Total time:248 minTotal time:128 min Time saved: 48 % 准干式加工典型应用Material:AlMgSi0,5F22 (DIN 1799 RD55) Machine:TRAUB TNA 300Speed range:05,000 rpm冷却润滑剂:原来 (wet)乳化液现在 (MQL)准干式润滑剂Wet machiningDry machiningnCutting speedFeedCutting speedFeedToolsVc m/minf mm/revToolsVc m/minfn mm/revFacing + rough turning4500,40Facing + rough turning4200,40Disposable drill 30470,12Disposable drill 303650,25Flat drilling 38770,15Flat drilling 383500,20Inside turning tool2000,30Inside turning tool3750,15Recessing tool420,05Hollowing 40H86000,06Inside turning tool800,10Inside turning tool1050,05Hollowing 40H81250,08Hollowing4500,40Smoothing1500,15Outside turning tool5200,15Outside turning tool3500,12Total time:746 minTotal time:142 min Time saved: 78 % 准干式加工典型应用定位环Material:AlMgSiPbF28 (DIN 1796 4KT50) Machine:TRAUB TNA 300Speed range:05,000 rpmCooling lubricant原来 (wet):乳化液现在(MQL)准干式润滑剂Wet machiningDry