The high speed with squirm cast-iron Chinese ink is machined

Casting pig cuts the formation of bits to be in casting pig, black lead submits flocculus form (graph 1) . Black lead piece because contain carbon to had been measured,be full close, high temperature forms with existence silicon. Flake graphite is a kind of soft impurity that conduces to cutting treatment. Graph the typical garrulous shape black lead in 1 casting pig (photograph by the S of SinterCast company.

Dr. Dawson is offerred) the fault line that because black lead appearance and black lead housing are acerb,the brim creates gifts the character of casting pig brittleness and low tensile strength. Cutting tool shearing force ruptures along this the line is ongoing, the mechanical shearing force that produces is lesser. As hind knife face always is not like already machining a face to maintain a contact, edge also is not from beginning to end with cut bits to maintain a contact. Be located in the material that cuts a point to be below new shearing force action, rupture along this line disintegrate, coming to be returned in horizontal then is in its horizontal falls to depend on the smallest fight force. Exposed black lead accent can lose among them black lead, become cut the knife after be being mixed before bits shedding and cutting tool face and achieve the lubricant between the surface newly. Similar casting pig such brittleness material, the brim that its machine damages easily, namely alleged avalanche (graph 2) . Graph of 2 casting pig rupture cut bits (photograph by the U of Darmstadt university.

Reuter PTW is offerred) as edge cut, bring about what pressure increases to wear away take the possibility that can make cast brim is torn off to increase. As a result of the permutation of measure of black lead housing and fault line, of the microstructure of the brim change infirmly can reduce make process the negative charge of cutting tool pressure that the brim ruptures or avalanche place needs. Already machined the surface with what hand stroke crosses casting pig, the black lead of the gray in the housing that can sweep casting pig surface to expose is pulverous. Because already was machined,can be infected with osculatory content this one characteristic, it is the origin of casting pig name. 2.

The configuration of the structure of physics of the black lead in cutting bits to form nodular cast iron of nodular cast iron, as more contrary than as it happens as casting pig photograph. if name, the black lead in ball iron is in the caky process of iron, because be changed additive by alloy (basically be magnesian) action, form round tie or bulbiform (graph 3) . Graph the bulbiform black lead in 3 nodular cast iron is in nodular cast iron, the sort of meeting in nonexistent casting pig is caused stress increases and rupture line. The base material between black lead antrum also won't appear casting pig in that way rupture. If the graph is shown 4 times, bulbiform black lead can be in below the action of pressure of cutting tool load before becoming the depart that cut bits, happen be out of shape. Graph of 4 nodular cast iron cut bits continuously this kind of micromechanism can produce what casting pig place does not have to extend a gender. Accordingly, edge must produce successive active force, achieve the shear strength of base material, ability is generated cut bits. Workpiece material forms steel to cut bits same cut bits to be in continuously edge is genteel over- . Because shear strength mixes the machinery of material higher to grind continuously (not be like casting pig rupture / cut process) , reason cuts the casting pig of prep above of unripe quantity of heat of the area. As a result of ball iron medicinal powder hot sex is poorer, increased to grind again. 58% what the heat conduction rate of ball iron is casting pig only. Ball iron thermal conductivity is not its cannot be used at making cylinder body crock build a the mainest reason. In cutting respect, this still can be reduced cut belong to medicinal powder heat energy force, the quantity of heat that cannot produce cutting division drops off very quickly. Its extend be an official to cause casting pig impossibly to machine in that way rupture, but total meeting produces burr. Because edge can become because of grinding blunt, as face of the knife after cutting tool wear away, compress the accretion of load, burr dimension increases subsequently. 3.

Squirm Chinese ink is cast-iron (of CGI) cut bits to form iron of squirm Mo Zhu (the black lead in CGI) shows coral or vermicular (graph 5) , because used the magnesium of exact amount,be, make flake graphite brim constrictive into the circle, but its tighten real rate and nodular cast iron to differ. Structure of this kind of metallographic won't be like the vermian form black lead of graph 5 CGI casting pig is same, can make in treatment stress increases to rupture with generation line, and won't resemble nodular cast iron in that way, cause the loss that heat conduction leads. This kind of character makes CGI makes the material of component of high strenth of a kind of production engine. Interpose of its fabricating characteristics extends gender and casting pig brittleness at ball iron between, cut bits to rupture for the part (graph 6) . The half successive form of graph 6 CGI cuts the test that bits Lamb company and place of other industry research organization do to make clear, compare with casting pig photograph, treatment CGI place needs machine tool power to want to increase 10% ～ 30% . The place when this kind of power increases quantity and contrast is used cast-iron about, for example, treatment blame alloy changes ferrite casting pig when place wants casting pig of pearlite of taller than treatment alloy with power low. Like casting pig, of CGI cutting is via shearing resistance the smallest black lead housing happens, but in be different from casting pig cutting, at black lead acute angle of antrum sharp edge falls generation crackle, the cutting of circular brim needs greater cutting power. Of the base material between soft qualitative black lead cut extremely be like nodular cast iron cut bits to fashion a process. The heat conduction of CGI leads the 78 ％ that are casting pig, the heat that this meeting increases cutting tool wears away effect, but the degree when won't achieving cutting nodular cast iron. Of CGI it is good to extend a gender, double what tensile strength and fatigue intensity are casting pig about, this meeting makes its produce burr more easily. When 1) thermochemistry reaction is undertaking with the low speed of 100m/min milling and the speed with 80m/min undertake getting cutting machining, the cutting tool that machines CGI wears away adjacent at machining casting pig. Problem of the most serious cutting tool life happens when the high speed that changes silicon and PCBN with nitrogen continuously machines CGI. The research of PTW Darmstadt announces, when high speed is machined, the manganese in casting pig and sulfur can form vulcanization manganese (MnS) covering layer, lubricant layer is formed in cutting tool surface (refer to graph 7a) . The 7MnS of edge invalidation graph that A) shows MnS layer B) not to have covering layer applies extensively already at improving the machinability of material to go up, include to apply MnS to produce easy cutting rolled steel. Be based on the treatment experience previously, enter MNS mix into pulverous metallurgy connecting rod in, machinability can raise 10 times. The chemical element of CGI includes the magnesium that is used at making black lead finalizes the design when solidify. However, magnesium and sulfur are had very good add up to a gender in person, the meeting when both mixes is lighted quickly. For this, CGI and nodular cast iron use desulphurization iron to stabilize this kind of reaction. The content of the sulfur in this kind of iron has the 1/10 of casting pig only, can't build MnS covering layer. Without the lubricant action of MnS layer, what mechanical attrition generates is hot, can make quickly edge invalidation (refer to graph 7b) . The alloy need of this kind of metallographic prevents parameter of treatment of intermittence of 2) low speed MnS impurity is used at assisting treatment, this is the prime cause that industry did not see high speed processes CGI data beforehand. The boring plan that industry accepts is with low surface speed (100 ～ 150m/min) and big feed cutting, with period the loss that offsets productivity (compare) with casting pig treatment. The influence of 3) low speed normally, when low rotate speed is machined, the power with cutting tool great need, rigid main shaft and tigidity hold clip. Current, the level of the big feed thrust that machine tool of treatment of common engine cylinder body and cutting tool have not achieve certain CGI to machine a requirement. Requirement CGI spare parts is designed now must can bear this kind of new treatment load. Accordingly, below most circumstance, what component machines load is finite yuan of analysis already with component function finite yuan of analysis is likewise serious. In machine program of current cylinder body of engine of deep skirt type, lamb company already reached the bearing limit of cylinder body itself when crock aperture thick boring. The load that the cylinder body treatment that rotate speed of this kind of low main shaft and the treatment strategy that big feed leads do not fit this kind of structure and CGI cause increases. Application raises speed and the capacity that reduce feed rate to may be returned be close to casting pig spare parts to process negative charge. Current common cutting cutting tool cannot be used effectively at this kind of treatment with faster temperature rise. Accordingly, need a kind it can susceptive cutting craft. 2, the cutting tool technology that treatment of CGI high speed combines tall stiffness machine tool and processing of distinctive cutting tool contrail to undertake is developed 2 times, make the high speed treatment of CGI becomes a possibility. (Normally high speed machines one word is to point to have " stable weaveform " treatment speed, use at strong wither only in the article this technology is in " an amount class " on the advantage of speed. ) 1.

High speed boring undertook changing one's costume or dress to circumgyrate type boring cutter, those who make suit to have geometrical figure and undertook mutiple level development, pass test and verify and obtained patent, eliminated inchoate unreasonable department. By U.

When Dr. Reuter undertakes in PTW special experiment, make cutting tool of this kind of circumgyrate achieves the rate of 800m/min, it is the cutting tool that has very macrobian lot exclusively. The task of a research of Lamb company is main now it is farther improve and enlarge this technology. Graph the spare partses of 8 CGI of high speed milling with 800m/min 2.

The milling test that place of orgnaization of research and development of company of Lamb of treatment of high speed milling has scored a success (referring to graph 8) to experiment is use agglomeration (SinterCast)CGI test specimen, undertake on the machining center of Jaguar 630 vertical of Lamb company. The purpose of the experiment is to evaluate what circumgyrate thick milling cutter provides to wear away. Its experiment place is with cutting parameter: 150mm of milling cutter diameter, rotate speed 800m/min, cutting deepness 5.

0mm, every tooth feed is 0.

2mm. Because test data origin is restricted, cut bits in what 100kg cut inside 9min time only (graph 9) . Inside whole cutting time, enlarge 150 times observation, did not discover edge has wear away apparently. Trial error already granted to eliminate normally, but the data of undermentioned test result still is worth to be carried. Graph when 9 treatment power and time relation are using nitrogen to change silicon bit, cutting 3.

5min.

Appeared to cut profound error after. Personnel of machine tool technology missed what use 15mm crucially to cut deep replace 5mm to cut deep experiment parameter. These information are very useful to deciding experiment condition is further. Main shaft power records: 28kW is when every tooth enters cutting. Spare parts surface is bright and clean degree did not suffer any effects, cutting tool and machine tool also did not discover apparent visible vibration. Cutting tool and machine tool have enough stiffness to deliver this kind of huge load effectively, did not appear mechanical failure. 3, bits appearance contrast is cut to be cutting tool of better understanding circumgyrate why to can machine a well to have longer cutting tool life with the speed of 800m/min when traditional cutting tool and cutting of circumgyrate cutting tool, need observes those who cut bits to fashion a process. Graph 10(is controlled) in observed again in front the form cutting bits that mentioned metallographic organizes, mix to traditional cutting tool of circumgyrate cutting tool cut bits to formed a process to make contrast. To traditional cutting tool (graph 10a) brings to bear on through bit cutting force, till achieve the shear strength of material. Before of face of the knife after the force of the flow resistance that cut bits of knife face is mixed wear away attrition force addition, make the general power that cutting tool place needs. In simplifying orthogonal model, appear the heat source of 3 respects, most apparent is to cut area of the knife before mixing calorific area. Face of the knife after sharp cutting tool is done not have wears away, calorific amount is very consequently small in the begining. If hold the post of its edge to wear away in the round,progress continues, can make the most serious calorific division. 3 calorific areas all arise and center at cutting blade ministry. The main reason that heat becomes cutting tool be no longer in force very quickly already became the main factor that material of all cutting tool develops. Bits is cut to form a process to pursue when A) tradition cuts bits to form cutting of cutting tool of process B) circumgyrate when cutting tool cutting 10 circumgyrate system is had in circumgyrate motion aggrandizement shearing force is mixed the good point that cuts bits shedding. The paper that elaborates reason of good qualities of this respect cutting tool is very much. Its are main the reason is, wear away to distributing on average along the circumference of 75mm of circular razor blade, this is the main good point that excel secures bit. Another main reason is its had been turned quickly by the cutting drop of fuel factor calorific area, new cutting feature turns to calorific area. Because difference of function of cutting tool cutting is very big, use this concept to perhaps can be in rotate speed 800, 1000 and further proof is become when 1200m/min. But no matter why be planted,common cutting tool all damages instantly. When elaborating circumgyrate cutting process, can make clear explanation (graph 10b) . Cut bits to flow in order to book surface of speed edge razor blade, cut bits to cut speed to be circumgyrate of actual measurement cutting tool about of circumferential speed very one of. Companion of strength of this cutting flow has weight of very little a shearing force joint action, bit is driven to turn on its circumgyrate axes. If graph 10a place is shown, face of the knife before cutting tool and the attrition motion between the underside that cut bits are not very big. Attrition of face of the knife before those who be main pyrotoxin is being made in cutting of groovy cutting tool is calorific, reduce in the cutting of cutting tool of circumgyrate razor blade not quite apparent. Now, we considered 3 kinds of possible comprehensive solutions: Wear away distributing to go up in whole periphery, had turned continuously the attrition of face of the knife before calorific area was eliminated is calorific area, consequently, we are understandable rate is improved in what achieve in CGI cutting. This kind of distinctive circumgyrate cutting technology is exclusive the method that can solve CGI high speed to machine. Expect with material of low speed carbon application is compared, field data makes clear, when machining casting pig, cutting tool life can rise 10 to 20 times. For example, north America an automobile factory, after running a loop 85000 times, hind of knife face wear away to be only 0.

127mm, and traditional cutting tool used treatment circulation 5000 times only, hind knife side wears away badly already. 4, once designed the cutting tool that fits workpiece material and work requirement correctly,the machine tool applies, below one link is a machine tool. The test of treatment of high speed CGI that Lamb company place does is to be in static undertake on the machine tool of 4 slideway ram that uses stiffness to have fine. Theoretic, because circumgyrate motion suspends causing,invalidation is, this meeting causes some kind of mechanical error. High speed moves in, every time breakdown already can be being machined apparently the mark that leaves cutting tool error. This trace explains, want to move successfully, need very tall stiffness. This kind of trace gives afore-mentioned now cutting deeply when 15mm happening error, classics analysis, it is machine tool stiffness insufficient. 1.

Produce burr more easily than casting pig about tool CGI spare parts, tool design must decide relevant element, make the treatment of higher cost, implementation wears away reasonably. The reasonable design of clamping apparatus tabulator, restrict the generation of burr as far as possible. Material is carried want security, should make sure cutting tool is whole wear away belt can complete rough machining process, is not to be in just achieved cutting tool life expectancy 10% make its discard as useless. Analysis of cost of life of the shortest cutting tool makes clear, go cost of burr working procedure is higher, just should appearing so the knife should be changed when burr. In current high speed milling and boring plan, those who use is 13.

5mm most diameter, this can offer the cutting tool point of view of better advantageous cutting, conduce to utmost reducing burr. Most diameter appearance can make material margin structure has enough strength, fight the deviation when cutting cease. The workpiece material of cutting terminal still stays in former, in order to need further treatment, accordingly can utmost reduces burr size. 2.

About the noise of ZdB is being reduced when noise CGI is machined, because data strength is on inferior degree,the part is, reduced damp character. These data get from machine tool of close pilot production, experiment, get confirming with outside data. On the tradition, milling cutter deserves to use the treatment of rigid machine tool, general when suitable mill attainable the result that prolongs cutting tool life. As a result of " suitable mill " the method can be being cut fashionable make bit cuts the biggest ply cut bits, had turned in order to compare the rate with rapid feed to be machined material, face of the knife after was being eliminated thereby chafes. The biggest impact bears when milling cutter razor blade is cutting a person, and cause impact vibration is the biggest (graph 11) . This kind of oscillatory meeting passes a machine tool, the most important is to pass workpiece to conduct. To all material, the amplitude harmony that reduces vibration to be able to reduce milling process is noisy, more such to CGI material. Graph bear of the 11 concussion in going against mill than be in with suitable mill photograph is the 15% distinctive circumgyrate as a result of plan of milling of this kind of high speed only cutting process, suffer " go against mill " model tatty influence is minor, and have inherent advantage. Now, we are OK can reduce milling to pound bear cut angle lesserly to cut work. Process of this kind of treatment is had can the majority of 2dB sound losing of sponge CGI material. Soft cut because reduced concussion bear to prolong life of main shaft bearing thereby,still have, and raised Bao Bi the advantage of exterior quality. 3.

Thick mill of the batch in the spare parts of CGI material cylinder body of the economy type that high speed processes processes a system, it is revealed can optimally " odd " the difference of finished cost. Final rough machining includes: The rough machining of all faces that require treatment and crock aperture. Fundamental facilities cost is the treatment parameter computation of the 100 traditional tool to 150m/min by use treatment speed. The speed that suggests to still use 800m/min undertakes milling and the speed boring jar that use 400m/min aperture. (The following holding cost all presses dollar computation) : Low speed machines main charge =$10, equivalent of 000 high speed machines charge =$7, 000 3 year odd cost saves =$6.

67/ 5 years of sheet cost saves =$4.

00/ 7 years of sheet cost saves =$2.

85/ existing research data makes clear, system of circumgyrate cutting tool has sheet cost advantage, and the manufacturing data of CGI material workpiece still remains to prove further. But, we had had the manufacturing data of casting pig. Data makes clear, cutting tool life can raise 17 times, can decrease 17 times to change a knife that is to say. If consider the time that reduces 17 times to change a knife and the change knife system automatically word that use inferior file, to transfer matic production, this involved production cost will be expense of very big brushstroke. 5, if conclusion is spent in the Gao Gang that has correct parameter system of circumgyrate cutting tool is used on the machine tool and complementary with process of creative cutting tool contrail, undertake to CGI material high speed machines be a likelihood. There are a lot of problems now is the task in Lamb company research and development project, in the meantime, lamb company is capable to solve any manufacturing problems, use this technology at producing a workshop with the rapiddest rate and small wind jaws. CNC Milling CNC Machining