铣削原理及铣刀磨损形式-

1、铳削三要素KCKkennametai:线性切削速度Vc沏深ap和每转走刀量f是切削三要 素。Vc: m/min米/分钟 ap: mm毫米fr(fn):mm/r 毫米 / 转切削三要素与刀具寿命KCKkennametal切削三要素与刀具寿命KCKkennametal切削三要素与刀具寿命KCKkennametal切削三要素与刀具寿命KCKkennametalD x it x n f ,. VC= “ (m/mm) 1000计算主轴速度(n)i/c x 1000n =Jt x l?c计算工作台进给量(旳)Z n x n x fz影响刀片寿命的原因有切削热，摩擦和切削抗力，这三者随着切削 速度的增加而

2、加剧最为强烈。切削三要素与刀具寿命KCKkennametal切削速度增加20%刀片磨损增加50%；走刀量增加20%刀片磨损增加 切深增加50%刀片磨损增加20%。20%；工件材料CMC代码HB硬度材质粗略分类Kc04(N/m7非合金钢类CMC01.1110Cv025%2200ElMALAmIE1ALCMC01.3150C<0.8%2600UlIVCMC01.5310C<14%3000低合金钢CMC02.1125-225未硕化2500CMC02.2220-420硕化3300商合金钢CMC03.11150-300退火态3000CMC03.21250-350硕化的工具钢4500超磧钢CM

3、C04.1>450硬化和调质的4500可锻铸铁CMC07.1110-145短們1200CMC07.2200-230长屑1300灰铸铁CMC08.1180低村伸强度1300CMC08.2260髙M伸强度.介金1500球墨铸帙CMC09.1160铁索体态1200SG铸铁CMC09.2250珠光体态2100铸钢类CMC06.1150非合金2200CMC06.2150-250低合金2500CMC06.3160-200髙介金3000不秀钢类CMC05.1150-270素体.马氏体13-25%2800CMC05.2150-275奥氏体線>8%, 18-25%2450CMC05.3275-425

4、淬火和调质马氏体0.12%C2800CMC05.4150-450沉积硕化3500铁基耐热合金CMC20.11180-230退火态或固溶处理3700CMC20.12250-320时效处理或固溶处理并时效3900银基耐热合金CMC20.21140-300退火态或固溶处理3500CMC20.22300-475时效处理或固溶处理并时效4150iCMC20.24200-425铸造或铸造并时效4150(钻基耐热合金CMC20.31180-230退火态或固溶处理3500CMC20.32270-320时效处理或固溶处理并时效4150CMC20.33220-425铸造或铸造并时效4150钛合金CMC23.140

5、0MPa通用的纯钛99.5%Ti1530CMC23.21950MPa退火态跑，近倒Q和钛羊1675CMC23.221050MPa时效态磁 合金 退火或时效态）0合金1690铝合金CMC30.1130-80锻造或冷拔态800CMC30.1275-150锻造和固溶处理800CMC30.2140-100铸造态900CMC30.2270-125铸造，固溶处理并时效400CMC30.380非合金，AL>=99%900高硅铝合金CMC30.410-14% SI14-16% SI150090°耐KC41(MKCEOKC52MIMKCftliftlKC935MKT35WPI3602302103

6、90训33DP216015(11c02402202C0P3150130120220200120P41C00801101009016019)140P513D1®1051251101C022520018JPfiSO709090140120M11901®12017015(11<i250220210M21®13)120150140130230210190M31C0驸120100170150K1270240220160150怖360SO2502302108007；«660K22101901502C019)1701301311102Ki240200180170

7、830670630K：1130旳）14017019)14011010090240221)2001701501Ci530470430N11210990N2S130：»4030S230®3030SJ40404040帥504)6080HiKZkennametal刀片材料和切削线速度Challenge to High Speed Cuttingu-lucp18001900Year2000KZkennametalKZkennametal高璽阿20 涂屋璽质金* *0硬唇金荊分钟 分k3氧比铝涂丿 金t陶瓷： 仙勤片：500米份饼0-0:.11L-anL-aii400-1000:100

8、0-3000/分饼KZkennametal铳削热和机械循环冷却加热KZkennametal© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential # of 79KZkennametal冷却© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential # of 79铳削刀具命名规则KKkennametal铳削刀具命名规则KKkennametalRSTCWDAHOVRound Square Triangle

9、 Rhomboidal Trigon Diamond 55 Parallelogram Hexagon Octagon Diamond 35八F sharp E Hone T- T landS- Honed TL- Light G- General H- HeavyCutting edge formEdge Prep SizeafenlnInsert HandRake FaceAngleLead angleWiper edge Clearanceserved. Propdetary and ConHOonba* 10 or 79铳刀设计铳削刀具类型铳削刀具命名规则主偏角前角齿数刀片命名规则刀片

10、刃口处理端面铳刀尺寸294© D1二有效刀具直径RR二径向前角K=键槽宽度H=刀体高度0 D 2 =最大直径ap=最大切削深度KZkennametal© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential # of 79KZkennametal© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential # of 79铳削刀具主偏角ISO作用:向主轴方向施加力不同切屑厚度切削深度切削直径KZk

11、ennametal© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential 13 of 79KZkennametal© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential # of 79主偏角对切屑厚度的影响（ANSI标准）KKkennametal© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential

12、 # of 79主偏角对切屑厚度的影响（ANSI标准）KKkennametal铳刀中心线位于工件的位置主偽角主偏角与切屑厚度主偏角齿进给量实际切屑厚度0°AA15°A.96 x A20°A.94 x A30°A.86 x A45°A.70 x A主偏角与切屑厚度主偏角齿进给量实际切屑厚度0°.010in. (0,25mm).010in. (0,25mm)15°.010in. (0,25mm).0096in. (0,25mm)20°.010in. (0,25mm).0094in. (0,24mm)30°.0

13、10in. (0,25mm).0086in. (0,22mm)45°.010in. (0,25mm).0071 in. (0,18mm)© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential 15 of 79主偏角KZkennametal©2012 Kennametal Inc. All rights reserved. Proprietary and Confidential 15 of 79KZkennametal径向前角()径向视图（上视图）轴向视图（前视图）©

14、;2012 Kennametal Inc. All rights reserved. Proprietary and Confidential # of 79双负角铳刀负向径向前角优点进给量更大刀片强度最大化切刃利用最大化缺点切削力更大将切屑推向工件后方会产生毛刺KZkennametal© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential 17 of 79双正向铳刀优点减少切削力机床功率消耗最小排屑远离丄件正向径向前角 Suitable for work hardening and soft

15、material缺点切刃薄弱 Not recommended for tough or hard material如定位不当，会加工时抬起工件KZkennametal正向轴向前角© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential 17 of 79KZkennametal© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential # of 79KZkennametalII正轴向前角© 20

16、12 Kennametal Inc. All rights reserved. Proprietary and Confidential # of 79正负角铳刀负向径向前角优点比之前提到的两种铳刀切削力小更容易切削提高了金属去除率MRR排屑远离工件KZkennametal正向轴向前角（轴向前角10°高剪切）（轴向前角V 10°剪切）© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential # of 79KZkennametal© 2012 Kennametal In

17、c. All rights reserved. Proprietary and Confidential # of 79KZkennametal© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential # of 79不等距齿距68°KZkennametal© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential 19 of 79KCKkennametal齒距梳齿每齒能有較大的進給量較大的齒槽

18、較大的切削深度偲 最小的切削馬力很少的齒數較多的齒接觸更高的毎分鐘進給量較小的切削深度偲較小的排屑空間多一點的切削馬力铳刀齿距KKkennametal©2012 Kennametal Inc. All rights reserved. Proprietary and Confidential 21 of 79铳刀齿距KKkennametal粗齿500 RPM .005 ipt 0.13 mm/z细齿7 Teethx0.13 mm/z (0.005 IPT)X500 RPM=445 mm/z (17.5 IPT)12 TeethX0.13 mm/tooth (0.005 IPT)X50

19、0 RPM=762 mm/min (30 IPT)©2012 Kennametal Inc. All rights reserved. Proprietary and Confidential 21 of 79铳刀旋转方向左手刀盘不常见/KZkennametal© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential # of 79刀片前刀面轮廓刀片前刀面轮廓不同的前角,KZkennametal© 2012 Kennametal Inc. All rights reserved

20、. Proprietary and Confidential 23 of 79KZkennametal© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential # of 79KZkennametal© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential # of 79KZkennametal-5° ,11° ,15°© 2012 Kennametal Inc.

21、 All rights reserved. Proprietary and Confidential # of 79刀片转位KKkennametal© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential # of 79刀片转位KKkennametal要实现最佳径向预轴向TIR,刀片方向应该与图标位置凹槽一致© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential # of 79铳刀基本操作切削方向刀

22、具定位刀具切入进刀角度平均切屑厚度 表面粗糙度KZkennametal© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential 25 of 79铳削技术顺铳（采用滚珠丝杆机器）推荐使用驱动系统有背隙时避免使用更好的刀具寿命提高了表面质量向下挤压工件KZkennametal逆铳（使用丝杆机器）用于淬硬材料及农而黑皮材料 拉离工件 差的刀具寿命 差的表面质屋 低效产生大屋的切削热© 2012 Kennametal Inc. All rights reserved. Proprietary a

23、nd Confidential # of 79KZkennametal選擇刀盤直徑工件好的KZkennametal不好的铳刀定位略微偏离中心线减少振刀机率在进刀和出刀的位置都有 非常好的切屑厚度KZkennametal9” (160 mm)直径刀具© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential # of 79KZkennametal© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential #

24、 of 79KZkennametal工件6" (100 mm)© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential 29 of 79刀具定位需要两次进刀 1/4到1/3刀具悬臂梁顺铳负向切入角避免使用整个刀具尽量使用主偏角选择齿距，保证2到4齿用于加工KZkennametal刀具定位© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential 29 of 79铳刀啮合进给方向薄切屑-6齿切削

25、不需要6KZkennametal厚切屑-需要4齿切削© 2012 Kennametal Inc. All rights reserved. Proprietary and Confidential 31 of 79铳刀啮合KKkennametal©2012 Kennametal Inc. All rights reserved. Proprietary and Confidential # of 79切削力Table FeedTable FeedWorkpieceCutterRotationTable FeedKCKkennametalTable Feed前角影響切削力切削

26、力正的軸向前角KZkennametalKZkennametal切削力負的軸向前角铳刀切削参数计算实例KKkennametal面铳刀直径80mm，6个刀片刃口，若刀片的切削速度为 150m/min,问主轴的转速是多少？如果每齿进刀量为 fz=0.2mm/z，问机床的工作台进刀量是多少？Secure the effection insert numbersKKkennametal圆弧插补铳削时走刀量的折算KKkennametalue comm?；O!1v = nxzcxfz vn = "f x Kyf = n x zc x fzDm + DcDm圆弧插补铳削时走刀量的折算KKkennam

27、etalRvalue conmangm假设铳刀有4个齿，切 削速度180m/min,要求 fz=0.17mm/z，问 Vfl 应 该是多少？v = nxzcxfz vn =叶 x K平均铳屑厚度和最大切屑厚度KCKkennametalness mKKkennametal铳削功率和扭矩的计wPower consuming and Torque forceP = 600 37X2Xkn (kW)Torque (Nm) = kW (nett) x 9549RPMKKkennametal铳 削功率 和扭矩的讦算Power consuming and Torque force面铳刀直径80mm, 6个刀

28、片刃口，铳削的材料分别为铸 铝合金(kc:800)和奥氏体不锈钢(kc:2400),若刀片的切 削速度为600m/min和150m/miii,每齿进刀为fz二02mm/z, 切深ap=4mm,切宽ae二60mm，问他们的铳削功率和扭矩N 铝=2388rpm vf铝=28 砧 mm/r p 铝=9.16kwT 铝=36NmN不锈钢=597rpmvf不锈钢=716mm/rp不锈钢=6<87kwazT不锈钢=109Nm常见工件材料的单位切削力Kc值工件材料CWIC代玛hbW®材贯相略另类KcO.4(N/mmI丰含全苗骐CMC01.1110C<0.25%2200CMC01.315

29、0C<0.8%2600CMC01.5310C<14%3000低含全钢CMC02.1125-2252500CMC02.2220-420硬化3300高合全钢CMC03.11150-300退火态3000CMC03.21250-350450048硬钥CMC04.1>450硬化和调慣的4500可媛铸铁CMC07.1 I 110-145短屑1200CMC07 2 I 200-2301300CMC08 11801300CMC08.2260ife拉itS® >合金1500CMC09.1 1160恢素体态1200SG榜旷CMC09.2250球光烁若-2100愣谄类CMC06 1

30、 I 150菲合金2200CMC06 2150-2502500CMC06.3 i 160-200盂含金3000不勞柄竞CMC05.1150-270素体，马氏体13-25%2800CMC05.2150-275奂氏体 >8%> 18-25%2450CMC05.3275-425马氏体0.12%C2800CMC05.4150-450沉积破亚3500铁基血热合金CMC20.11180-230退火态或固厢处理3700CMC20.12250-320吋效处慶或固运处理并时效3900蝮蕊血迪含金CMC20.21140-300堰业惑戒固溥处理3500CMC20.22300-475时效处理或固洛处理并时

31、效4150CMC20.24200-425撐造或悽造并时奴4150铭基期热合金CMC20.31180-230退火态或固沼处理3500CMC20.32270-320时效处理或固洛处理并时效4150CMC20.33220-425粽谨戒特造并时放4150钛合金CMC23.1400MPa通用的纯杖丿99.5%Ti1530CMC23.21950MPa想灭志出近做加钛舎金1675CMC23.221050MPa时效态皈审合金 退火或时奴态的0合全1690铝合金CMC30.1130-80擾造或怡拡怎800CMC30.1275-150锻谨和固溶处理800CMC30.2140-100900CMC30.2270-12

32、5様造,固溶处理并时效400CMC30.380菲合全'AL>=99%900高硅宙合金CMC30.410-14% SI14-16% SI1500KENNAME1AI：Dodeka系列Indexable Milling TeamsKCKkennameiai:y vuiu rxemidinetal Inc.All rights reserved.Proprietary and Confidential 44Dodeka MAX 45° -特点KKkennametaly vuiu rxemidinetal Inc.All rights reserved.Proprietary

33、and Confidential 44y vuiu rxemidinetal Inc.All rights reserved.Proprietary and Confidential 44在加工钢件，不锈钢，铸铁和高温合金材料时不同材质的刀片都具有卓越的性能y vuiu rxemidinetal Inc.All rights reserved.Proprietary and Confidential 44Dodeka系列y vuiu rxemidinetal Inc.All rights reserved.Proprietary and Confidential 44y vuiu rxemid

34、inetal Inc.All rights reserved.Proprietary and Confidential 44市场上最全面的铳刀系列y vuiu rxemidinetal Inc.All rights reserved.Proprietary and Confidential 44y vuiu rxemidinetal Inc.All rights reserved.Proprietary and Confidential 44Dodeka 45°Dodeka High-Feed12CutroInsert HN.J0905Ap1 max = 4.5 mmAp1 max

35、= 2 mmy vuiu rxemidinetal Inc.All rights reserved.Proprietary and Confidential 44KZkennametalDodeka Max 45°12 * ®Insert HN.J1307Ap1 max = 8mm©2010 Kennametal Inc. All rights reserved. Proprietary and Confidential 45Dodeka Mini -刀片特点KKkennametalooooooHNGJ-LDJHNGJ-LD綁山ldHNPJ-GDHNPJ-HDRo

36、ughingFinishingLight MachiningFinishingGeneral MachiningHeavy RoughingI I I lNl I II I Nl I s s M | B| S s非铁金属和铝介佥粗加铝合金和非铁佥属不锈钢和高温合金修光刃用于加工钢件.不通用加工首选适合各鱼型加工首选.适介各工和半精加工首选精加工修光刃轻型加工首选锈钢.铸铁和高隘合金种材料种材料Periphery GroundPeriphery GroundPeriphery GroundPeriphery GroundPSTSPSTSnEo32HDEdge Prep: Sharp+ Honec

37、uyc rrepru i *mim + fiuik?© 2011 Kennametal Inc. All rights reserved. Proprietary and Confidential 46Dodeka Mini -特点KZkennametal并非刀尖首先切入工件 刃口设计强壮，刀片前角 大.可以轻快切削© 2011 Kennametal Inc. All rights reserved. Proprietary and Confidential 47Dodeka Mini -刀体特征KKkennametal© 2011 Kennametal Inc.

38、 All rights reserved. Proprietary and Confidential #Dodeka Mini -刀体特征KKkennametalDodeka Mini HF (15-)Dodeka Mini 45°Dodeka Mini HD (60-)© 2011 Kennametal Inc. All rights reserved. Proprietary and Confidential #Dodeka Mini -刀体特征KKkennametal© 2011 Kennametal Inc. All rights reserved. Pr

39、oprietary and Confidential #Dodeka Mini -刀体特征KKkennametal0 D10 D1 MAXLead Angle253&214,53245?214,54053?214,55063?214,56376?214,58093,214,50 D10 D1 MAXLead Angle2533,244,83240,244,84048,244,85058.244,86371,244,88088,244,8100108,244,8125133,244,80 D10 D1 MAXLead Angle4046,2595056,2596369,2598086,2

40、59100106,259125131,259© 2011 Kennametal Inc. All rights reserved. Proprietary and Confidential #Dodeka Mini -刀体特征KKkennametal© 2011 Kennametal Inc. All rights reserved. Proprietary and Confidential #Dodeka Mini -刀体特征KKkennametal© 2011 Kennametal Inc. All rights reserved. Proprietary a

41、nd Confidential #Dodeka Mini 坡鉄能力KKkennametal© 2011 Kennametal Inc. All rights reserved. Proprietary and Confidential 49Dodeka Mini 坡鉄能力KKkennametalLiniar Ramp Length =APMAXlangens Kamp Angie© 2011 Kennametal Inc. All rights reserved. Proprietary and Confidential #Dodeka Mini 坡鉄能力KKkenname

42、tal© 2011 Kennametal Inc. All rights reserved. Proprietary and Confidential #Dodeka Mini 坡鉄能力KKkennametalDodeka Mini 45°D1AP MAXRamp AngleRamp Length253,22?963,2323,22?187,3403,21,6114,6503,22?091 ?6633,21,6114,6803,21,2152,81003,21,0183,31253,20?8229,2Dodeka Mini HD (60° )D1AP MAXRam

43、p AngleRamp Length404,41,2210,1504,40,9280,1634,40,7360J804,40,5504,21004,40,4630,21254,40,3840,3© 2011 Kennametal Inc. All rights reserved. Proprietary and Confidential #Dodeka Mini 45°-螺旋插补KKkennametal© 2011 Kennametal Inc. All rights reserved. Proprietary and Confidential #Dodeka Mini 45