车刀选择及应用.ppt

1、车刀的选择与应用,Tool Holder & Boring Bar Identification刀杆与镗刀杆定义,TopClamping夹紧,KL Pin Top andHole Clamping,Screw Clamping螺纹夹紧,MCLNR 164D Insert Holding Method夹紧方式,New D-KC Kenclamp,MCLNR 164D Insert Shape MCLNR 164D 刀片形状,MCLNR 164D Lead Angle MCLNR 164D 主偏角,MCLNR 164D Clearance Angle MCLNR 164D 侧隙角,MCLNR 16

2、4D Hand of Tool MCLNR 164D 手动刀杆,MCLNR 164D Holder Shank Size MCLNR 164D 刀杆柄部尺寸,MCLNR 164D Inscribed Circle Size MCLNR 164D 内切圆尺寸,SNMP-K,TNMG,CNMG,WNMG,MCLNR 164D Holder Shank Size MCLNR 164D 刀杆尺寸,Qualified Length适当的长度,Toolholder Identification System刀杆定义系统,MCLNR 1 6 4 D,The Mechanical Method of Inse

3、rt Retention刀片机械夹紧方式,Inch英制,Insert Clearance 刀片后角,Shank Size柄部尺寸,Toolholder Identification System刀杆定义系统,MCLNR25 25 M 12,The Mechanical Method of Insert Retention刀片机械夹紧方式,Metric,Boring Bar and Head ID System镗刀杆和镗刀头定义系统,A16 U M SK N R 4,Bar orHead Type 刀杆和刀头类型,BarDiameter 刀杆直径,Insert Size I.C.内切圆直径,Ha

4、nd ofBar 刀杆方向,Insert Clearance 刀片后角,BarStyle 刀杆形式,InsertShape 刀片形状,Method of Holding Insert刀片夹紧方式,Bar Length 刀杆长,Inch英制,Boring Bar and Head ID System镗刀杆和镗刀头定义系统,A25 R M SK N R 12,Bar orHead Type 刀杆和刀头类型,BarDiameter 刀杆直径,Insert Edge length 刀片切削刃长.,Hand ofBar 刀杆方向,Insert Clearance 刀片后角,BarStyle 刀杆形式,I

5、nsertShape 刀片形式,Method of Holding Insert 刀片夹紧方式,Bar length 刀杆长,Metric公制,Insert Holding Assemblies刀片夹紧组件,TopClamping,KL Pin Top andHole Clamping,Screw Clamping,New D-KC Kenclamp,Kenclamp Assembly组件,Quick release clamping system reduces machine downtime 快速松开夹紧系统减少，加工时间 1.5 Turns to release Insert 1.5转

6、松开刀片 Robust clamping design reduces chatter improves tool life 刚性夹紧设计减少振动，延长刀具寿命 The Kenclamp design ensures insert repeatability and seating Kenclamp设计确保刀片重复和定位精度 Fewer moving part than competitive systems 比竞争者系统更少的拆卸零件 Torx Plus hardware increases clamping forces and hardware life One wrench fits

7、both the shim screw and clamp screw 一把扳手适合刀垫螺钉和夹紧螺钉,KL Series Clamp Assemblies KL系列夹紧组件,The KL system provides rigid clamping KL系统提供刚性夹紧 Tools may be used with or without clamp Optional hardware is available for use with thicker inserts,Kendex Clamp Assembly Kendex夹紧组件,Top Notch Turning Clamp Assemb

8、ly Top Notch 车削夹紧组件,Top Notch style clamping the same stable clamping geometry that makes Top Notch threading and grooving system so popular Top Notch 夹紧类型-稳定的夹紧形状使Top Notch 用于螺纹和切槽加工 Simple lock and unlock - easy one screw clamping system简单的夹紧松开，单螺钉锁紧系统 Application ideally suited for high-speed rou

9、ghing to finishing of cast iron parts.应用-适于高速粗加工到精加工铸铁零件 The clamping system provides the ultimate in stability and strength, especially in turn and face combinations machining 夹紧系统提供最大的稳定性和强度，特别在 Insert stability leads to longer more predictable tool life and consistent part tolerances 刀片稳定性导致更长的可预

10、测的刀具寿命和稳定的零件尺寸公差,Top Notch Profiling Clamp Assembly Top Notch 仿形加工夹紧组件,Screw On Insert Clamp Assembly Screw On刀片夹紧组件,Screw螺钉,Insert刀片,OD Tooling Matrix外圆刀具,Make sure you refer to the index in the back of the catalog when replacing hardware. 当取代零件时，参考产品目录后面的索引 The index defines the correct hardware f

11、or a specific insert IC and thickness. 索引详细说明适合刀片内切圆半径和厚度的正确元件 Exploded assembly views are defined in the index. The index defines the correct chip breaker part number for a specific IC insert and thickness 索引详细说明适合刀片内切圆半径和厚度正确断屑器零件号码 The index also defines hardware specifications 索引详细说明零件使用,Hardwar

12、e Index零件索引,What do we need to consider when selecting a tool holder? 当选择刀杆时，你需要考虑什么？,Selecting a Tool Holder刀杆选择,Machine & Turret Type机床类型 Shank Size刀柄尺寸 Insert Geometry (Pocket Shape) 刀片形状 Positive or Negative正或负前角 Lead Angle主偏角 Workpiece Configuration Requirements工件形状要求 Strength of Pocket and Hol

13、ding Mechanism夹紧机构的刚性,Selecting a Tool Holder刀杆选择,Back Rake径向前角,Side Rake侧前角,Positive and Negative Rakes正前角和负前角,Increasing Lead Angle增大的主偏角,.100,.100,.009,.007,Increased Radial Force 增大径向力 More Deflection 易塑性变形,Decreased Chip Thickness 减小切削厚度 Higher Feed Capability 具有高速加工能力,Reduced Entry Shock 减少金属去

14、除量 Less Depth of Cut Notch 减小切深 Fewer Problems with Interrupted Cuts 断续切削较好,Lead Angle Selection Criteria主偏角选择标准,Machine rigidity机床刚性 Set-up rigidity Workpiece configuration工件形状 Availability of tool positions in turret车床上刀具的位置 Economics - one tool for several operations 经济性-一把刀具多用途,Profiling Operati

15、on轮廓加工,Workpiece Configuration Requirements 工件形状要求,Boring Bar Selection镗刀杆选择,ID Tooling Matrix外圆刀杆,The Science of Boring镗刀杆技术,Boring / TurningWhats the Difference?镗和车有什么不同之处？,C / L,Turning = Short Overhangs 车削=短悬伸量 Turning Clearance - Not Diameter Dependent 车削公差-与直径没关系 I.D. Machining = Longer Overha

16、ngs 内孔加工=长的悬伸量 Boring Clearance - Variable, depending on Rake Angle and Workpiece Diameter 镗削公差-变化的，依赖前角和工件直径,Workpiece工件,What do we need to consider when selecting a boring bar?当选择镗刀杆时你需要考虑什么？,Workpiece工件,Depth of Hole孔的深度 Diameter of Hole孔的直径 D.O.C. Requirements需要的切深 Special Features (Profiling, T

17、hreading, Grooving etc.)特殊特征（仿形，螺纹，切槽等加工） Finish Requirements精度要求 Interruptions是否断续加工,Machine机床,What do we need to consider when selecting a machine for a boring operation? 当选择机床进行镗孔操作时，你需要考虑什么？,Machine机床,Workpiece Chucking Method刀具夹紧方式 Coolant Plumbing and Application Method of Checking Center Heig

18、ht检测中心高的方式 Boring Bar Holding Method 镗刀杆夹紧方式,METHOD OF HOLDING夹紧方式,Sleeve, Split Bushing or Collet 导套侧平面弹簧夹头,Better较好,Good好,METHOD OF HOLDING夹紧方式,Better,Good好,Collet弹簧夹头,Best,METHOD OF HOLDING夹紧方式,Coolant - Through or Not?冷却液-内冷或没有内冷,Eliminate Problems with Chip Disposal- Thermal Shock Loss of Rigid

19、ity?,Cutting Tool切削刀具,Boring Bar & Insert镗刀杆与刀片 What do we need to consider when selecting a boring bar and an insert? 当选择镗刀杆和刀片时你需要考虑什么？,Boring Bar镗刀杆,Length to Diameter Ratio长径比 Composition组成 Rake & Clearance Angles 前角和后角 Center Height中心高 Lead Angle/Cutting Forces主偏角/切削力 Chip Clearance容屑空间,Length

20、to Diameter Ratio长径比,Length长度,Diameter直径,SHORTEST LENGTH最短长度,A BAR WITH A 3” OVERHANG IS OVER TWICE AS STIFF AS A BAR WITH A 4” OVERHANG,1” Dia. Basic Rigidity,1 1/4” Dia. 2 1/2 Times Increase in Rigidity,1 1/2” Dia. 5 Times Increase in Rigidity,2” Dia. 16 Times Increase in Rigidity,Boring Bar Compo

21、sition镗刀杆组成,Steel钢4/1 Heavy Metal (Machined)重金属刀杆4/1 to 6/1 Steel/DeVibrator消振钢刀杆6/1 Carbide (Must be ground)硬质合金刀杆（必须精磨）6/1 Carbide/DeVibrator硬质合金消振刀杆8/1 Standard Tunable Boring Bar标准钨镗刀杆6/1 to 10/1 Special Carbide/DeVibrator消振特殊硬质合金刀杆over 10/1 Special Tunable Boring Bar 特殊钨镗刀杆10/1 to .,Composition

22、组成,Length to Diameter长径比,DeVibrator Boring Bar消振镗刀杆,Damper package provides a controlled means of adjusting the behavior of a tool阻尼部件提供调整刀具性能的方法,How it works怎样工作:,Heavy Metal Mass重金属块,O-ringsO型环,Adjusting collar调整套,Adjustment screw调整螺钉,Tuned Tooling调整刀具,L/D ratios 4:1 4:1 to 6:1 6:1 to 8:1 8:1 to 1

23、0:1 Over 10:1,Boring Bar镗刀杆 Steel钢 Steel, Heavy Metal, Carbide钢，重金属，硬质合金 Carbide De vibrator, Tuneable消振重金属，可调整 Carbide composite /De vibrator, Tuneable Special Composite Bars, Tuneable特殊结构镗刀杆，可调整,Where would tuneable boring bars be applied?可调整镗刀杆应用在哪,Tuneable indicates first choice可调整第一选择,Tuned Too

24、ling调整刀具,Standard inch boring products标准英制镗刀杆产品 5/8”, ” 1”, 1 1/4”, 1 1/2”, 1 3/4”, 2”, 2 1/2”, & 4” Standard metric boring products标准公制镗刀杆产品 25mm, 32mm, 40mm & 50mm A complete range of specials完全特殊的领域 Interchangeable heads for screw on inserts designed for 1” diameter tuneable boring bars 1”直径可调镗刀杆

25、，适于screw on 刀片的可更换镗刀头,Tuned Tooling Product Offering 提供可调整刀具产品,Radial and Axial Rake Angles径向和轴向前角,Neg.,Pos.,AXIAL,Radial径向,Radial轴向,Neg.,Pos.,On Center Condition,On Center Condition,Radial Rake NegativeAxial Rake Negative径向和轴向前角都是负的,K,o,Radial Rake NegativeAxial Rake Positive径向前角负和轴向前角正,K,o,Boring

26、Clearance Negative镗刀后角负,Boring Clearance Positive镗刀后角正,Lead Angle主偏角,CUTTING FORCE DIRECTION切削力方向,Space for Chips & Finish切屑空间与精加工,More Deflection Less Feed易变形小进给,Less Deflection More Feed 变形小进给大,Torsional Force扭力矩,Direction of Forces力的方向,THE “F” DIMENSION F尺寸,THE GREATER THE “F” DIMENSION, THE GREA

27、TER THE TORSIONAL LOAD F尺寸越大扭力矩越大,Chip Clearance容屑空间,Rule of Thumb:经验法则 The Chip Clearance Should Be Twice the Depth of Cut (Width of the Chip)容屑空间应该是切深的2倍,Example例如: Depth of Cut is .125”切深是0.125” 2 x .125” = .250” Chip Clearance容屑空间,CHIP CONTROL OPTIONS (machine)机床切削控制选择,FEED RATE - Usually Increa

28、se进给率-通常增加 SPEED - Increase速度-增加 DEPTH OF CUT - Usually Increase切深-通常增加 COOLANT - Through the Bar, More Pressure or Redirect 冷却液-内冷，更大压力,CHIP CONTROL OPTIONS (insert)刀片切削控制选择,LEAD ANGLE - Change to redirect 主偏角-直接改变 GEOMETRY - Tighter (closer to tip) or Positive 几何形状-夹紧（夹紧力靠近刀尖）或正前角 NOSE RADIUS - Sm

29、aller刀尖半径-更小 EDGE PREP - Sharp, hone, or T-land? 切削刃-锋利刃，倒圆或倒棱,Prevent Chip Packing In Blind Holes盲孔加工时，防止卷屑,Note: Neutral Axial Rake, Not Negative Light DOC Due to Lead Angle 0轴向前角不是负的，小切深根据主偏角,Feed进给,Key Elements of Good Tool Application好的刀具应用关键因素,Tool Maintenance刀具维护 Overhang悬伸量 Centerline对中性 Too

30、l Holding Method刀具夹紧方式 Application Hints使用提示,Inspect the Pocket检查刀窝,Inspect the Clamping检查夹紧,Lockpin/Screw Inspection(Insert Location)检查锁紧销/螺钉刀片位置,p. 77,Overhang悬伸长,Overhang悬伸量,To Reduce Tool Pressure减少刀具压力,Positive Rake Tool Geometry使用正前角形状 Minimum Lead Angle最小主偏角 Smallest Possible Nose Radius尽可能小的

31、刀尖半径 Reduce the Depth of Cut减少切深 Reduce Feed减少进给,Centerline对中心性,Deflection in Small Diameter Boring镗小直径孔时变形,Interruptions断续加工,Increase Speed增大速度 Increase Lead Angle增大主偏角 Larger Nose Radius大的刀尖半径 Reduce Feed减少进给 Thicker Insert厚的刀片 Stronger Geometry (Round, Square etc.)更强的刀片形状（圆形，正方形等） Consider Edge Prep (Hone or T-Land) 考虑切削刃（倒圆或