附录附录1英文原文Mold high speed milling processing technologyFirst/ foreword In the modern mold production/ along with to models artistic and the function must obtain more and more high/ models the internal structure to design more and more complex/ the mold contour design day by day is also complex/ the free curved surface accounts for the proportion to increase unceasingly/ the corresponding mold structure also designs more and more complex/ These all set a higher request to the mold processing technology/ not only should guarantee the high manufacture precision and the surface quality/ moreover must pursue the processing surface artistic/ Along with is unceasingly thorough to the high speed processing engineering research/ is processing the engine bed/ the numerical control system/ the cutting tool system/ CAD/ especially Correlation technology and so on CAM software develops unceasingly under the impetus/ high speed processes the technology more and more many to apply in the mold cavity processing and the manufacture/ The numerical control high-speed cutting processing took in the mold manufacture a most important advanced manufacture technology/ is the collection is highly effective/ high quality/ the low consumption in a body advanced manufacture technology/ Is opposite in the traditional machining/ its cutting speed/ entered to the speed had the very big enhancement/ moreover cut the mechanism not to be same/ The high-speed cutting caused the machining to have the leap/ its specific power metal excision rate enhanced 30%40%/ the cutting force reduced 30%/ the cutting tool working durability enhanced 70%/ remained hotly large scale reduces in the work piece cutting/ the low step shudder vanished nearly/ Along with the cutting speed enhancement/ unit time semi-finished materials material removing rate increased/ the cutting time reduced/ the processing efficiency enhanced/ thus reduced the product manufacture cycle/ enhanced the product market competitive power/ At the same time/ the high speed processing small amount entered quickly causes the cutting force to reduce/ the scrap high speed discharged reduced the work piece cutting force and the thermal load distorts/ enhances the rigidity to be bad and the thin wall components machining possibility/ Because cutting force reducing/ the rotational speed enhancement causes the cutting system the operating frequency to be far away the engine bed the low step natural frequency/ but the work piece surface roughness is most sensitive to the low step frequency/ from this reduced the surface roughness/ In mold high hard steel stock (HRC45HRC65) in the processing process/ uses the high-speed cutting to be possible to substitute for the working procedure which the electrical finishing and rubs truncates polishes/ thus has avoided the electrode manufacture and the time-consuming electrical finishing/ large scale reduced fitters polishing with to throw the light quantity/ Thin wall mold work piece more and more needs which regarding some markets in/ the high speed milling also may smoothly complete/ moreover in the high speed milling CNC processing center/ a mold attire clamps may complete the multiplex step of processing/The high speed processing technology has had the huge influence to the mold processing craft/ changed the traditional mold processing to use the annealing - milling processing - heat treatment - to rub truncates or the electric spark machining - manually polishes/ polishes and so on the complex long technical process/ even might use the high-speed cutting processing substitution original complete working procedure/ The high speed processing technology besides may apply in the hard mold cavity direct processing (in particular half precision work and precision work)/ in EDM aspect and so on electrode processing/ fast type manufacture also obtained the widespread application/ The mass productions practice indicated that/ the application high-speed cutting technology may save in the mold following processing 80% handwork to grind the time approximately/ saves the processing cost expense nearly 30%/ the mold face work precision may reach 1 m/ the cutting tool cutting efficiency may enhance 1 time/Second/ high speed milling processing engine spindle The high-speed cutting technology is one of machining technology main development directions/ it along with foundation technology the and so on CNC technology/ microelectronic technology/ new material and new structure development but steps a higher stair/ Because the mold processes particular as well as high speed processing technology own characteristic/ (processed engine bed/ numerical control system/ cutting tool to the mold high speed processing related technology and the craft system and so on) proposed processed a higher request compared to the traditional mold/1/ High stable engine spindles strut partThe high-speed cutting engine lathe and so on supports the part to be supposed to have very well moves/ the static rigidity/ hot rigidity and best damping characteristic/ The majority of engine beds all use high grade/ the high rigidity and Gao Kangzhang the gray iron took the strut part material/ some engine bed companies also increase the high damping characteristic in the foundation polymer concrete/ by increases its vibration-proof and the thermo-stability/ this not only may guarantee the engine bed precision is stable/ also may prevent when cutting the cutting tool inspires trembles/ Uses the enclosed lathe bed design/ the overall casting lathe bed/ the symmetrical lathe bed structure and has the densely covered stiffener and so on also enhances the engine bed stable important measure/ Some engine bed companies research and development departments in design process/ but also uses the modality analysis and the finite element structure computation and so on/ optimized the structure/ stably causes the engine bed strut part to be reliable/2/ Engine spindles main axleThe high speed engine bed main axle performance is the realization high-speed cutting processing important condition/ The high-speed cutting engine bed main axle rotational speed scope is 10000100000m/Min/ the main axle power is bigger than 15kW/ Is not bigger than 0/005mm through the main axle compressed air or axial play between the cooling system control hilt and the main axle/ Also requests the main axle to have the fast vertical speed/ to assign the performance which the position is fast stops (namely to have extremely high angle addition and subtraction speed)/ therefore the high speed main axle often uses the liquid static pressure bearing type/ the air static pressure bearing type/ the thermo-compression nitriding silicon (Si3N4) the ceramic bearing magnetism aerosol bearing type iso-structuralism form/ Lubricates uses technology and so on oil gas lubrication/ splash lubrication/ The main axle cools uses the main axle interior water cooling generally or air cooled/3/ The actuates system of the engine spindleIn order to satisfy the mold high speed processing the need/ high speed processes the engine bed the actuation system to be supposed to have the following characteristic/ (1) high entering for speed/ The research indicated that/ regarding the minor diameter cutting tool/ enhances the rotational speed and each tooth enters for the quantity is advantageous in reduces the cutting tool attrition/ At present commonly used entering for the speed range is 2030m/Min/ like uses leads greatly the ball bearing guide screw transmission/ enters may reach 60m/ min/ Uses the straight line electrical machinery then may enable to achieve 120m/min/ (2) high acceleration/ Has the good acceleration characteristic to the three dimensional complex curved surface silhouette high speed processing request actuation system/ the request provides the driver which the high rapid advance or progress gives (to enter speed approximately 40m/ min/ the 3D outline processing speed is 10m/Min)/ can provide 0/4m/S2 to 10m/The s2 acceleration and reduces the speed/ The engine bed manufacturer mostly uses the entire closed loop position servo-control slightly to lead/ the great size/ the high grade ball bearing guide screw or leads greatly many guide screws/ Along with the electrical machinery technology development/ the advanced straight line electric motor already was published/ and the success applied in the CNC engine bed/ The advanced straight line direct motor drive enable the CNC engine bed no longer to have the mass inertia/ in advance/ question and so on lag and vibration/ sped up the servo speed of response/ increased the servo-control precision and the engine bed processing precision/ 4/ Numerical control system The advanced numerical control system is guaranteed the mold complex curved surface high speed processing quality and the efficiency key aspect/ the mold high-speed cutting processing to the numerical control system basic request is/ (1) high speed numerical control return route (Digital control loop)/ including/ 32 or above 64 bit parallel processors and 1/5Gb hard disk/ Extremely short straight line electrical machinery sampling time/ (2) speed and acceleration feed-forward control (Feed forward control)/ Digital actuation system crawling control (Jerk control)/ (3) advanced inserts makes up the method (to insert based on the NURBS transect makes up)/ by obtains the good surface quality/ the precise size and the high geometry precision/ (4) pretreats (Look-ahead) the function/ The request has the large capacity cushion register/ may read in advance and inspects many segments (for example the DMG engine bed to be possible to reach 500 segments/ the Simens system may reach a 10002000 segment)/ in order to when is processed the superficial shape (curvature) changes may promptly adopt changes for measure and so on speed by avoids cutting and so on/ (5) the error compensatory function/ including because the straight line electrical machinery/ the main axle and so on gives off heat the hot error which causes to compensate/ the quadrantal error compensates/ the measurement system error compensates and so on the function/ In addition/ the mold high-speed cutting processing very is also high to the data transmission speed request/(6) the traditional data connection/ like the RS232 serial mouth transmission speed is 19/2kb/ but many advanced processings centers have used the ether local area network (Ethernet) to carry on the data transmission/ the speed may reach 200kb/5/ Cooling lubricationThe high speed processing uses the belt coating the hard alloy tools/ in high speed/ the high temperature situation does not need the cutting compound/ the cutting efficiency to be higher/ This is because/ The milling main axle high speed revolves/ the cutting compound if achieved the cutting area/ first must overcome the enormous centrifugal force/ Even if it overcame the centrifugal force to enter the cutting area/ also was possible as a result of the cutting area high temperature but to evaporate immediately/ the cooling effect very small did not even have/ At the same time the cutting compound can cause the cutting tool edge of a sword the temperature intense change/ is easy to cause the crack the production/ therefore must pick the oil used/Gas cooling lubrication dry type cutting way/ This way may use the compressed gas rapidly the cutting which the cutting area produces/ thus the massive cuttings hotly will carry off/ at the same time might forms extremely thin microscopic protective film after the atomization lubricating oil in the cutting tool edge of a sword and the work piece surface/ but effectively will lengthen the cutting tool life and enhances the components the surface quality/Third/ high-speed cutting processing hilt and cutting toolBecause time high-speed cutting processing the centrifugal force and the vibration influence/ requests the cutting tool to have the very high geometry precision and the attire clamps the repetition pointing accuracy as well as the very high rigidity and the high speed transient equilibrium security reliability/ Because time high-speed cutting processing big characteristic and so on centrifugal force and vibration/ the traditional 7/24 taper hilt system is carrying on the high-speed cutting to watch appears the obvious rigidity insufficient/ the redundant pointing accuracy is not high/ the axial size not steadily grades the flaw/ the main axle inflation causes the cutting tool and clamps the organization nature heart the deviation/ affects the cutting tool the transient equilibrium ability/ At present applies many is the HSK high speed hilt and the overseas nowadays popular fastening -like hilt/ the fastening -like hilt has the heating system/ the hilt all uses the awl department to contact generally with the main axle end surface also/ its rigidity is good/ but the cutting tool commutactivity misses/ a hilt only can install one kind of connection diameter the cutting tool/ Because this kind of heating system quite is expensive/ when initial period uses the HSK kind of hilt system then/ When enterprises high speed engine bed quantity surpasses above 3/ uses the fastening -like hilt quite to be appropriate/The cutting tool is in the high-speed cutting processing one of most active important factors/ it is affecting the processing efficiency/ the production cost and the product processing precision directly/ The cutting tool must withstand load and so on high temperature/ high pressure/ friction/ impact and vibration in the high speed processing process/ the high-speed cutting cutting tool should have the good machine capability and the thermostability/ namely has the good anti- impact/ the wearability and resists heat the weary characteristic/ The high-speed cutting processing cutting tool technological development speed is very quick/ application many like diamonds (PCD)/ cubic boron nitride (CBN)/ ceramic cutting tool/ coating hard alloy/ (carbon) titanium nitrides hard alloy TIC (N) and so on/In the processing cast iron and in the alloy steel cutting tool/ the hard alloy is the most commonly used cutting tool material/ Hard alloy tools resistance to wear good/ but the solidity ratio cube boron nitride and the ceramics are low/ In order to enhance degree of hardness and the superficially attractive fineness/ uses the cutting tool coating technology/ the coating material for the titanium nitrides (TIN)/ the aluminium nitride titanium (TIALN) and so on/ The coating technology causes the coating by the sole coating development for multilayered/ the many kinds of coating material coating/ has become one of enhancement high-speed cutting ability essential technical/ The diameter in the 1040mm scope/ also has the carbon titanium nitrides coating the hard alloy bit to be able to process the Luo river degree of hardness to be smaller than 42 materials/ but the titanium nitrides aluminum coating cutting tool can process the Luo river degree of hardness is 42 even higher materials/ When high-speed cutting steel products/ the cutting tool material should select the hot rigidity and the fatigue strength high P kind of hard alloy/ the coating hard alloy/ the cubic boron nitride (CBN) and the CBN compound cutting tool material (WBN) and so on/ Cuts Truncates the cast iron/ should select the fine grain K kind of hard alloy to carry on the rough machining/ selects the compound nitrided silicon ceramics or the crystal combination cube boron nitride (PCNB) the compound cutting tool carries on the precision work/ When precise processing non-ferrous metal or nonmetallic material/ should select crystal combination diamond PCD or the CVD diamond coating cutting tool/ When choice cutting parameter/ in view of the circular shear blade and a ball milling cutter/ should pay attention to the effective diameter the concept/ The high speed milling cutting tool should press the balance design manufacture/ The cutting tool front angle must be smaller than the conventional cutting tool front angle/ the clearance angle is slightly big/ The host vice- cutting edge attachment point should the cavetto or the lead angle/ increases the vertex angle/ prevents the knife point place hot attrition/ Should enlarge nearby the knife point the cutting edge length and the cutting tool material volume/ enhances the cutting tool rigidity/ Is safe in the guarantee and satisfies the processing request under the condition/ the cutting tool hangs extends as far as possible short/ cutter body central toughness is friends with/ The hilt must be sturdier than the cutting tool diameter/ connects the handle to assume but actually the pyramidal/ by increases its rigidity/ As far as possible central the refrigerant hole in the cutting tool and the cutting tool system/ A ball end mill must consider effectively cuts the length/ the cutting edge must be as far as possible short/ two spiral grooves balls end mill usually uses in the thick mill complex curved surface/ four spiral grooves balls end mill usually uses in the fine mill complex curved surface/Fourth/ mold high speed processing craft and strategyThe high speed processing including take removes the remainder as the goal rough machining/ the residual rough machining/ as well as take gains the high grade processing surface and the slight structure as the goal half precision work/ the precision work and the mirror surface processing and so on/1/ Rough machiningThe mold rough machining essential target is pursues in the unit time material removing rate/ and is half precision work preparation work piece geometry outline/ In the high speed processing rough machining should adopt the craft plan is the high cutting speed/ Gao Jin giving rate and the small cutting specifications combination/ The contour processing way is one processing way which the multitudinous CAM software uses generall
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