US20190224763A1 - Method of setting heat-resistant alloy cutting conditions and method of cutting heat-resistant alloy - Google Patents

Method of setting heat-resistant alloy cutting conditions and method of cutting heat-resistant alloy Download PDF

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Publication number
US20190224763A1
US20190224763A1 US16/329,093 US201716329093A US2019224763A1 US 20190224763 A1 US20190224763 A1 US 20190224763A1 US 201716329093 A US201716329093 A US 201716329093A US 2019224763 A1 US2019224763 A1 US 2019224763A1
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Prior art keywords
cutting
heat
resistant alloy
cutting tool
amount
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US16/329,093
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English (en)
Inventor
Jun Eto
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Mitsubishi Heavy Industries Ltd
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Mitsubishi Heavy Industries Ltd
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Assigned to MITSUBISHI HEAVY INDUSTRIES, LTD. reassignment MITSUBISHI HEAVY INDUSTRIES, LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ETO, JUN
Publication of US20190224763A1 publication Critical patent/US20190224763A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C3/00—Milling particular work; Special milling operations; Machines therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C5/00—Milling-cutters
    • B23C5/02—Milling-cutters characterised by the shape of the cutter
    • B23C5/10—Shank-type cutters, i.e. with an integral shaft
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C5/00—Milling-cutters
    • B23C5/02—Milling-cutters characterised by the shape of the cutter
    • B23C5/10—Shank-type cutters, i.e. with an integral shaft
    • B23C5/1009—Ball nose end mills
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q15/00—Automatic control or regulation of feed movement, cutting velocity or position of tool or work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q15/00—Automatic control or regulation of feed movement, cutting velocity or position of tool or work
    • B23Q15/007—Automatic control or regulation of feed movement, cutting velocity or position of tool or work while the tool acts upon the workpiece
    • B23Q15/013—Control or regulation of feed movement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q15/00—Automatic control or regulation of feed movement, cutting velocity or position of tool or work
    • B23Q15/007—Automatic control or regulation of feed movement, cutting velocity or position of tool or work while the tool acts upon the workpiece
    • B23Q15/08—Control or regulation of cutting velocity
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/416—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by control of velocity, acceleration or deceleration
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C2220/00—Details of milling processes
    • B23C2220/48—Methods of milling not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23C—MILLING
    • B23C2222/00—Materials of tools or workpieces composed of metals, alloys or metal matrices
    • B23C2222/88—Titanium
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/37—Measurements
    • G05B2219/37336—Cutting, machining time
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T409/00—Gear cutting, milling, or planing
    • Y10T409/30—Milling
    • Y10T409/30084—Milling with regulation of operation by templet, card, or other replaceable information supply
    • Y10T409/300896—Milling with regulation of operation by templet, card, or other replaceable information supply with sensing of numerical information and regulation without mechanical connection between sensing means and regulated means [i.e., numerical control]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T409/00—Gear cutting, milling, or planing
    • Y10T409/30—Milling
    • Y10T409/303752—Process
    • Y10T409/303808—Process including infeeding

Definitions

  • the present invention relates to a method of setting a heat-resistant alloy cutting condition in cutting a heat-resistant alloy with a cutting tool, and a method of cutting a heat-resistant alloy.
  • Patent Literature 1 With the intention to discharge heat generated during cutting and to perform cooling, such a cutter is conventionally known (for example, see Patent Literature 1) that has a plurality of straight teeth or helical teeth formed around the outer circumference of the cylinder, a flute formed for each tooth, and a through-hole to circulate air or coolant around the tooth surface.
  • the ratio between the number of cutter teeth and the cutter diameter is set at at least 0.75:1.
  • This cutter has a cutting speed of the teeth of at least 400 teeth-per-second.
  • Patent Literature 1 United States Patent Application Laid-open No. 2004/0258496
  • Examples of a material to be machined include heat-resistant alloys such as titanium alloy. Titanium alloy has lower thermal conductivity and is thus easy to accumulate machining-induced heat generated during cutting. In addition, titanium alloy has higher Young's modulus and has larger cutting resistance. Machining-induced heat is thus easy to be generated. Titanium alloy is therefore usually cut at a lower cutting speed to suppress generation of such machining-induced heat. Such a lower cutting speed reduces the efficiency of work, and as a solution to suppress a reduction in the efficiency of work, the cutter has an increased amount of cutting per tooth.
  • Cutting work at a lower speed with an increased cutting amount per tooth needs a large cutting tool and accordingly needs a large machine to which such a large cutting tool is installed.
  • Cutting work is therefore difficult to be performed on a small piece having a small portion to be machined, and a large piece is the only option to be machined, which makes the tool less versatile. Consequently, a wide variety of cutting tools are necessary depending on the type of piece to be machined.
  • a large piece needs to be fixed. An increase in the size of machine is therefore inevitable.
  • the present invention has an object to provide a method of setting heat-resistant alloy cutting conditions and a method of cutting a heat-resistant alloy, which are widely applicable and capable of suppressing a reduction in the efficiency of cutting work on the heat-resistant alloy.
  • a method of setting a heat-resistant alloy cutting condition according to the present invention is a method of setting a heat-resistant alloy cutting condition that is used to set a cutting condition under which a heat-resistant alloy is cut with a cutting tool mounted on a spindle.
  • the cutting tool includes a long shaft mounted on the spindle and extended in an axial direction and a plurality of teeth disposed on an outer circumference of the shaft.
  • the cutting condition includes a radial direction cutting amount in a radial direction of the cutting tool.
  • the method includes setting the radial direction cutting amount of the cutting tool in a range from the smallest radial direction cutting amount to the largest radial direction cutting amount.
  • the cutting tool can cut the heat-resistant alloy with at least a tooth of a plurality of teeth of the tool constantly in contact with the heat-resistant alloy. This can suppress vibration of the cutting tool, which is caused with the teeth of the cutting tool separated from the heat-resistant alloy. Moreover, with this configuration, the cutting tool can cut the heat-resistant alloy with three or more teeth of the teeth of the tool not in contact with the heat-resistant alloy. This can suppress chatter vibration of the cutting tool, which is caused with three or more teeth of the tool contacting the heat-resistant alloy. Suppressing vibration of the cutting tool can increase the amount of cutting of the cutting tool and thus can suppress a reduction in the efficiency of cutting work on the heat-resistant alloy.
  • a small cutting tool has a small amount of cutting in the radial direction, which is beneficial in suppressing generation of machining-induced heat per tooth.
  • the efficiency of cutting work can be improved by increasing the number of cuttings per revolution by increasing the number of teeth and further improved by increasing the rotational speed of the cutting tool.
  • the cutting condition includes a condition under which the cutting tool cuts the heat-resistant alloy at a constant radial direction cutting amount.
  • This configuration can achieve stable cutting work by making the diameter direction cutting amount of the cutting tool constant.
  • the cutting condition includes a condition under which L/D is equal to or greater than 3.5.
  • This configuration can increase the length of projection of the cutting tool, which allows the cutting tool, fixed to the spindle, to be less rigid and to have lower eigenfrequency.
  • the eigenfrequency of the cutting tool gets close to a usable rotational speed of the spindle, the amount of cutting of the cutting tool is increased, which can further improve the efficiency of cutting work.
  • the ratio L/D needs to be equal to or greater than 3.5, preferably equal to or greater than 4.5, optimally 5.
  • a cutting condition (L/D) ⁇ N consisting of L/D and N, is preferably from 40 to 120 when L/D is 3.5 to 5, and preferably equal to or greater than 90 when L/D is larger than 5.
  • the tool has, for example, a diameter D of 20 mm and a projection length L of 70 mm.
  • a stable rotational speed of the spindle is calculated using a certain formula based on a parameter including an eigenfrequency of the cutting tool; a cutting speed of the cutting tool is calculated using a certain formula based on a parameter including the calculated stable rotational speed; and when the calculated cutting speed is given as Vcn [m/min], the cutting condition includes a condition under which the cutting tool fulfilling 100 [m/min] ⁇ Vcn [m/min] ⁇ 300 [m/min] is selected.
  • This configuration allows the cutting tool to cut the heat-resistant alloy at a proper cutting speed with the spindle rotating at a stable rotational speed.
  • a plurality of the stable rotational speeds are calculated; a plurality of the cutting speeds are calculated based on the stable rotational speeds; a largest cutting speed of the cutting speeds, fulfilling 100 [m/min] ⁇ Vcn [m/min] ⁇ 300 [m/min] is selected; and the cutting condition includes a condition under which the stable rotational speed corresponding to the selected cutting speed is set as a spindle rotational speed of the spindle.
  • This configuration allows the cutting tool to cut the heat-resistant alloy at a higher cutting speed with the spindle rotating at a stable rotational speed, which can improve the efficiency of cutting work.
  • the cutting condition includes a feed rate per tooth of the cutting tool, and the feed rate per tooth of the cutting tool is set based on a cut cross-sectional area per tooth, given by multiplying a thickness of removal by a width of cutting, and an amount of inclination of the cutting tool with respect to the axial direction.
  • This configuration can achieve a proper feed rate per tooth of the cutting tool, which enables more proper cutting.
  • the feed rate per tooth of the cutting tool is reset to be smaller than the feed rate previously set.
  • the feed rate per tooth can be reset to a proper rate.
  • Another method of setting a heat-resistant alloy cutting condition is method of setting a heat-resistant alloy cutting condition that is used to set a cutting condition under which a heat-resistant alloy is cut with a cutting tool mounted on a spindle.
  • the cutting condition includes a condition under which L/D is equal to or greater than 3.5.
  • This configuration can increase the length of projection of the cutting tool, which allows the cutting tool, fixed to the spindle, to be less rigid and to have lower eigenfrequency.
  • the eigenfrequency of the cutting tool gets close to the rotational speed of the spindle, the amount of cutting of the cutting tool is increased, which can further improve the efficiency of cutting work.
  • a method of cutting a heat-resistant alloy according to the present invention includes cutting the heat-resistant alloy using the cutting tool under the cutting condition set by the method of setting a heat-resistant alloy cutting condition according to any one of the methods of setting a heat-resistant alloy cutting condition.
  • This configuration allows even a small cutting tool to perform sufficient cutting work on the heat-resistant alloy without reducing the efficiency of work. It is therefore possible to provide cutting work on even a small piece. This configuration can therefore make the tool versatile while suppressing a reduction in the efficiency of cutting work on the heat-resistant alloy.
  • FIG. 1 is a schematic view of a cutting tool according to an embodiment.
  • FIG. 2 is a flowchart of a method of setting cutting conditions according to the embodiment.
  • FIG. 3 is an illustrative drawing relating to the amount of cutting of the cutting tool in the radial direction.
  • FIG. 4 is an illustrative drawing relating to the feed rate per tooth of the cutting tool.
  • FIG. 5 is an example of a graph relating to the amount of cutting in the axial direction varying with the spindle rotational speed.
  • FIG. 6 is another example of a graph relating to the amount of cutting in the axial direction varying with the spindle rotational speed.
  • FIG. 7 is an example of a graph relating to the machining time and the efficiency of cutting work for the amount of cutting in the axial direction.
  • FIG. 8 is an example of a graph relating to the volume of removal for the amount of cutting in the axial direction.
  • FIG. 9 is an example of a graph relating to the width of wear varying with the volume of removal.
  • FIG. 10 is an example of a graph relating to the width of wear varying with the machining time.
  • FIG. 1 is a schematic view of a cutting tool according to an embodiment.
  • FIG. 2 is a flowchart of a method of setting cutting work conditions according to the embodiment.
  • FIG. 3 is an illustrative drawing relating to the amount of cutting of the cutting tool in the radial direction.
  • FIG. 4 is an illustrative drawing relating to the feed rate per tooth of the cutting tool.
  • FIG. 5 is an example of a graph relating to the amount of cutting in the axial direction varying with the spindle rotational speed.
  • FIG. 6 is another example of a graph relating to the amount of cutting in the axial direction varying with the spindle rotational speed.
  • a heat-resistant alloy is used as a material to be machined.
  • the heat-resistant alloy include titanium alloy and nickel-base alloy. Heat-resistant alloys have lower thermal conductivity and higher Young's modulus.
  • the cutting tool 10 is a tool usually referred to as an end mill and includes a long shaft 14 mounted on a spindle 5 and extended in an axial direction and a plurality of teeth 15 formed around the outer circumference of the shaft 14 .
  • the cutting tool 10 in the present embodiment has a larger number of teeth with the intention to decrease the amount of cutting per tooth to suppress generation of machining-induced heat per tooth, while to increase the amount of cutting per revolution of the cutting tool 10 .
  • the cutting tool 10 used in the later-described cutting test includes, for example, 15 teeth 15 on the outer circumference of the shaft 14 .
  • the cutting tool 10 has an outer diameter D of, for example, about 20 mm.
  • the cutting tool 10 is mounted with its base end fixed to the spindle 5 and its front end portion projecting from the spindle 5 .
  • the spindle 5 rotates the mounted cutting tool 10 at a certain rotational speed (the spindle rotational speed) in the cutting process.
  • the cutting tool 10 has a projection length L, which is the length from the spindle 5 to the front end.
  • the cutting tool 10 has a larger projection length L that allows the cutting tool 10 to be less rigid, with the intention to make the eigenfrequency of the cutting tool 10 mounted on the spindle 5 close to the spindle rotational speed of the spindle 5 .
  • the projection length L of the cutting tool 10 in the axial direction is determined, for the outer diameter D, to have the ratio L/D at equal to or larger than 3.5.
  • This ratio L/D is one of the cutting conditions.
  • the ratio L/D needs to be equal to or greater than 3.5, preferably equal to or greater than 4.5, and optimally 5.
  • a cutting condition (L/D) ⁇ N consisting of L/D and N, is preferably from 40 to 120 when L/D is 3.5 to 5, and preferably equal to or greater than 90 when L/D is larger than 5.
  • the method of setting cutting conditions sets such cutting conditions that include the type of cutting tool 10 to be used, the spindle rotational speed of the spindle 5 , the amount of cutting in the axial direction of the cutting tool 10 , the amount of cutting in the radial direction of the cutting tool 10 , and the feed rate per tooth of the cutting tool 10 , specifically.
  • the method of setting cutting conditions selects the type of cutting tool 10 to be used (Step S 10 ).
  • a cutting tool 10 is selected that fulfills the above ratio L/D and the number of teeth N.
  • the selected cutting tool 10 is mounted on the spindle 5 and is, for example, tapped, to measure the eigenfrequency ⁇ f of the cutting tool 10 mounted on the spindle 5 (Step S 12 ).
  • a stable rotational speed Sn of the spindle 5 is calculated using the following predetermined formula (1) based on parameters including the measured eigenfrequency ⁇ f of the cutting tool 10 (Step S 14 ).
  • the stable rotational speed Sn in the above formula (1) is obtained on each of the natural numbers n of 1 to 3, and three stable rotational speeds Sn are therefore calculated in the present embodiment.
  • a cutting speed Vcn of the cutting tool 10 is calculated using the following predetermined formula (2) based on parameters including the calculated stable rotational speed Sn.
  • the calculated cutting speed Vcn is subsequently determined whether to satisfy the cutting condition (Step S 16 ).
  • Vcn Sn ⁇ D ⁇ 1000 (2)
  • Vcn a cutting speed [m/min] (n: 1, 2, 3)
  • D the outer diameter of the cutting tool
  • the cutting speed Vcn in the above formula (2) is obtained on each of the natural numbers n of 1 to 3, and three cutting speeds Vcn are therefore calculated in the present embodiment.
  • the cutting tool 10 to be used needs to fulfill the condition of 100 [m/min] ⁇ Vcn [m/min] ⁇ 300 [m/min].
  • Step S 16 it is determined whether at least one cutting speed Vcn of the obtained three cutting speeds Vcn is in the above range of cutting speed.
  • Step S 16 if all the obtained three cutting speeds Vcn are out of the above range of cutting speed (No at Step S 16 ), the process returns to Step S 10 to make another selection for the cutting tool 10 .
  • Step S 16 if at least one of the obtained three cutting speeds Vcn is in the above range of cutting speed Vcn (Yes at Step S 16 ), the spindle rotational speed of the spindle 5 is set based on the cutting speed Vcn (Step S 18 ).
  • a stable rotational speed Sn corresponding to the cutting speed Vcn is set as the spindle rotational speed of the spindle 5 . If two or more cutting speeds Vcn fulfill the cutting condition at Step S 16 , at Step S 18 , a stable rotational speed Sn corresponding to the highest cutting speed Vcn of the cutting speeds Vcn is set as the spindle rotational speed of the spindle 5 . In this manner, at Step S 18 , a spindle rotational speed is set as one of the cutting conditions.
  • An axial direction cutting amount Ad the amount of cutting in the axial direction of the cutting tool 10 , as one of the cutting conditions, is subsequently set based on the projection length L of the cutting tool 10 , the flute length of the tooth 15 , and the form to be shaped of the heat-resistant alloy (Step S 20 ).
  • a radial direction cutting amount Rd the amount of cutting in the radial direction of the cutting tool 10 is subsequently set as one of the cutting conditions (Step S 22 ).
  • the radial direction cutting amount Rd of the cutting tool 10 is set in the range from a smallest radial direction cutting amount Rd_min to a largest radial direction cutting amount Rd_max.
  • the smallest radial direction cutting amount Rd_min and the largest radial direction cutting amount Rd_max will now be described with reference to FIG. 3 .
  • the smallest radial direction cutting amount Rd_min [mm] indicates the radial direction cutting amount in which one of a plurality of teeth 15 is constantly in contact with the heat-resistant alloy. With none of the teeth 15 contacting the heat-resistant alloy, separation of the teeth 15 of the cutting tool 10 from the heat-resistant alloy causes vibration of the cutting tool 10 .
  • Rd_min the smallest radial direction cutting amount
  • R the radius of the cutting tool
  • ⁇ the angle between the teeth
  • the largest radial direction cutting amount Rd_max [mm] indicates the radial direction cutting amount in which three or more teeth 15 of a plurality of teeth 15 are not in contact with the heat-resistant alloy. Three or more teeth 15 of the cutting tool 10 in contact with the heat-resistant alloy cause chatter vibration of the cutting tool 10 .
  • the largest radial direction cutting amount Rd_max is given by the following formula (4).
  • Rd_max the largest radial direction cutting amount
  • R the radius of the cutting tool
  • ⁇ the angle between the teeth
  • the radial direction cutting amount Rd of the cutting tool 10 is set in the range from the smallest radial direction cutting amount Rd_min to the largest radial direction cutting amount Rd_max at Step S 22 , and the feed rate per tooth of the cutting tool 10 , as one of the cutting conditions, is subsequently set (Step S 24 ).
  • the feed rate per tooth fz [mm/tooth] is set based on the cut cross-sectional area per tooth, given by multiplying the thickness of removal by the width of cutting, and the amount of inclination of the cutting tool 10 with respect to the axial direction.
  • the thickness of removal h is calculated using the following formula (5).
  • the amount of inclination of the cutting tool 10 is calculated by a prior process simulation relating to the cutting.
  • ⁇ h ( D 2 + fzsin ⁇ ⁇ ⁇ ) - ( D 2 ) 2 + ( sin 2 ⁇ ⁇ - 1 ) ⁇ fz 2 ⁇ ⁇ h ⁇ : ⁇ ⁇ the ⁇ ⁇ ⁇ thickness ⁇ ⁇ of ⁇ ⁇ removal ⁇ ⁇ D ⁇ : ⁇ ⁇ the ⁇ ⁇ outer ⁇ ⁇ diameter ⁇ ⁇ of ⁇ ⁇ the ⁇ ⁇ cutting ⁇ ⁇ tool ⁇ fz ⁇ : ⁇ ⁇ the ⁇ ⁇ feed ⁇ ⁇ rate ⁇ ⁇ per ⁇ ⁇ tooth ( 5 )
  • the thickness of removal h and the amount of inclination ⁇ of the cutting tool 10 are calculated, the thickness of removal h is determined whether to be smaller than a preset threshold ⁇ (a constant) (h ⁇ ), and the amount of inclination ⁇ is determined whether to be smaller than a preset threshold ⁇ (a constant) ( ⁇ ) (Step S 26 ).
  • Step S 26 upon determination that neither conditions h ⁇ nor ⁇ is fulfilled (No at Step S 26 ), the process returns to Step S 22 , and the radial direction cutting amount Rd is newly set in the range from the smallest radial direction cutting amount Rd_min to the largest radial direction cutting amount Rd_max.
  • Step S 26 upon determination that the conditions h ⁇ and ⁇ are fulfilled (Yes at Step S 26 ), the radial direction cutting amount Rd and the feed rate fz, set at Step S 22 and Step S 24 , are set as the cutting conditions, and the process of setting cutting conditions ends.
  • a dotted line L 1 is a conventional line in which the method of setting cutting conditions of the present embodiment is not adopted.
  • a solid line L 2 in FIG. 5 is a line in which the radial direction cutting amount Rd, set from Step S 22 to Step S 26 in FIG. 2 , is applied as the cutting condition.
  • the line L 2 of the present embodiment, in which the radial direction cutting amount Rd is set has been recognized to have the axial direction cutting amount Ad increased compared to the conventional line L 1 .
  • a solid line L 3 of FIG. 6 is a line in which the cutting tool 10 selected at Step S 10 to S 16 in FIG. 2 is applied as the cutting condition.
  • a plurality of peaks have been recognized to shift into the range of cutting speed usable by the spindle 5 , compared to the conventional line L 1 . Because the peaks on the line L 3 are portions where the eigenfrequency ⁇ f of the cutting tool 10 and the spindle rotational speed S of the spindle 5 resonate with each other, making higher peaks shift to the usable cutting speed range allows selection of a spindle rotational speed having a larger axial direction cutting amount Ad.
  • FIG. 7 is an example of a graph relating to the machining time and the efficiency of cutting work for the axial direction cutting amount.
  • FIG. 8 is an example of a graph relating to the volume of removal for the axial direction cutting amount.
  • the cutting tool 10 has 15 teeth 15 and has an outer diameter D of 20 mm and a projection length L of 80 mm.
  • the radial direction cutting amount Rd of the cutting tool 10 is constant during the cutting process on the heat-resistant alloy.
  • the abscissa gives the axial direction cutting amount Ad, and the ordinate on the left gives the machining time [H], and the ordinate on the right gives the average MMC (the efficiency of cutting work) [cc/min].
  • Ad the axial direction cutting amount
  • H the machining time
  • MMC the efficiency of cutting work
  • the abscissa gives the axial direction cutting amount Ad, and the ordinate gives the volume of removal [cc].
  • Ad the axial direction cutting amount
  • cc the volume of removal
  • an axial direction cutting amount of equal to or larger than 20 mm gives a volume of removal of 6883 cc, a machining time of 105 min, and an average MMC of 65.6 cc/min. It has further been recognized that an axial direction cutting amount of smaller than 20 mm gives a volume of removal of 501 cc, a machining time of 49 min, and an average MMC of 10.2 cc/min. It has been further recognized that the overall axial direction cutting amount gives a volume of removal of 7384 cc, a machining time of 154 min, and an average MMC of 47.9 cc/min.
  • FIG. 9 is an example of a graph relating to the width of wear varying with the volume of removal.
  • FIG. 10 is an example of a graph relating to the width of wear varying with the machining time.
  • the cutting tool 10 used in FIG. 9 and FIG. 10 is the same as that used in FIG. 7 and FIG. 8 .
  • the abscissa gives the volume of removal [cc], and the ordinate on the left gives the width of wear [mm].
  • a white rhombus ( ⁇ ) indicates the width of wear on the edge of the front end of the tooth 15 in the axial direction
  • a white rectangle indicates the width of wear at the center of the tooth 15 in the axial direction
  • a white triangle indicates the width of wear on the edge of the rear end (located about 70 mm away from the front edge) of the tooth 15 in the axial direction.
  • the tooth 15 of the cutting tool 10 further wears with an increase in the volume of removal. In this case, however, the width of wear substantially linearly changes. It has therefore been recognized that the wear stably proceeds and that the change in the width of wear is small.
  • the abscissa gives the machining time [min], and the ordinate on the left gives the width of wear [mm].
  • a white rhombus ( ⁇ ) indicates the width of wear on the edge of the front end of the tooth 15 in the axial direction
  • a white rectangle indicates the width of wear at the center of the tooth 15 in the axial direction
  • a white triangle indicates the width of wear on the edge of the rear end (located about 70 mm away from the front edge) of the tooth 15 in the axial direction.
  • the tooth 15 of the cutting tool 10 further wears with an increase in the machining time. In this case, however, as is the case of FIG. 9 , the width of wear substantially linearly changes. It has therefore been recognized that the wear stably proceeds and that the change in the width of wear is small.
  • the cutting tool 10 can cut a heat-resistant alloy with at least a tooth of a plurality of teeth 15 of the cutting tool 10 constantly in contact with the heat-resistant alloy.
  • the constant contact can suppress vibration of the cutting tool 10 , which is caused with the teeth of the cutting tool 10 separated from the heat-resistant alloy.
  • the cutting tool 10 can cut the heat-resistant alloy with three or more teeth 15 of the teeth 15 of the cutting tool 10 not in contact with the heat-resistant alloy. This manner can suppress chatter vibration of the cutting tool 10 , which is caused with three or more teeth 15 of the cutting tool 10 contacting the heat-resistant alloy.
  • Suppressing vibration of the cutting tool 10 can increase the amount of cutting (the volume of removal) of the cutting tool 10 and thus can suppress a reduction in the efficiency of cutting work on the heat-resistant alloy. This manner can increase the amount of cutting of the cutting tool 10 , and therefore allows even a small cutting tool 10 to perform sufficient cutting work without reducing the efficiency of work. It is therefore possible to provide cutting work on even a small piece and to make the tool versatile. Furthermore, suppressing vibration of the cutting tool 10 can suppress wear of the teeth 15 of the cutting tool 10 and thus can extend the life of the cutting tool 10 . Such a small cutting tool 10 cuts a small amount in the radial direction, which is beneficial in suppressing generation of machining-induced heat per tooth. The efficiency of cutting work can be improved by increasing the number of cuttings per revolution by increasing the number of teeth and further improved by increasing the rotational speed of the cutting tool 10 (the spindle 5 ).
  • the cutting tool 10 cutting a constant amount in the radial direction allows stable cutting work.
  • the cutting tool 10 is allowed to have a larger projection length L by setting the rate L/D at 3.5 or greater.
  • the cutting tool 10 fixed to the spindle 5 is therefore allowed to be less rigid, which can decrease the eigenfrequency ⁇ f of the cutting tool 10 .
  • the eigenfrequency of the cutting tool 10 gets close to a usable spindle rotational speed of the spindle 5 , the amount of cutting of the cutting tool is increased. In this manner, the efficiency of cutting work can be further improved.
  • the cutting tool 10 can cut a heat-resistant alloy at a proper cutting speed Vcn with the spindle 5 rotating at a constant rotational speed.
  • a stable rotational speed corresponding to the highest cutting speed Vcn of a plurality of cutting speeds Vcn is allocated for the spindle rotational speed of the spindle 5 , which can improve the efficiency of cutting work.
  • a proper feed rate fz per tooth of the cutting tool 10 can be set, which enables proper cutting work.
  • the feed rate fz can be reset. This configuration allows setting of a proper feed rate fz per tooth.
  • a proper cutting tool 10 is selected, and a proper radial direction cutting amount Rd is set.
  • the method of setting cutting conditions may include either of the cutting conditions.
  • the method of setting cutting conditions may include Step S 10 to Step S 16 without including Step S 22 of FIG. 2 or may include Step S 22 without including Step S 10 to Step S 16 of FIG. 2 .

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Milling Processes (AREA)
  • Numerical Control (AREA)
  • Human Computer Interaction (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
US16/329,093 2016-09-02 2017-07-03 Method of setting heat-resistant alloy cutting conditions and method of cutting heat-resistant alloy Abandoned US20190224763A1 (en)

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JP2016-171978 2016-09-02
JP2016171978A JP6929626B2 (ja) 2016-09-02 2016-09-02 耐熱合金の切削加工条件設定方法及び耐熱合金の切削加工方法
PCT/JP2017/024390 WO2018042866A1 (ja) 2016-09-02 2017-07-03 耐熱合金の切削加工条件設定方法及び耐熱合金の切削加工方法

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CN109641291A (zh) 2019-04-16
EP3492206A1 (en) 2019-06-05
US20210078125A1 (en) 2021-03-18
EP3492206A4 (en) 2019-09-11
WO2018042866A1 (ja) 2018-03-08
US11925992B2 (en) 2024-03-12
JP6929626B2 (ja) 2021-09-01
CN109641291B (zh) 2021-05-28
JP2018034287A (ja) 2018-03-08

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