Dihart铰刀培训

1、Technology of reaming1Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REFine tooling of boresDefinitionFine tooling of bores is every kind ofCuttingForming WashMachining to get ISO IT quality of a bore with IT 9 or better.2Focus Training Aluminium-Bea

2、rbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / RE Methods for Micro Finishing of Bores CuttingFormingWashGeometrically determined cutting shape (Tool cutting edge)Geometrically not determined cutting shape (Cutting grain)Single blade toolMultiple blade toolBonded grainLoosegrai

3、nPress-polishingInternal superfinish turningFineboringReamingGrindingHoningPolish grindingLappingVibration lappingPolish lappingCalibratingBrunishingErodePolish engraveElectrolytic machining Polish electrolytic3Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwic

4、klung / RERange of Application: Drilling, Countersinking, Reaming16151413121110987654321001IT- QualittRange for reamingDrillingCountersinkingOnly possible in special casesManufacturing tolerance on workpieces for all industriesFor gauging and measurement equipmentFor small TolerancesFor Large Tolera

5、nces4Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REProcess- and Machine capability reached if:1. Process capability: Cpk1,33 2. Machine capability: Cmk1,67C- Rule:To realize process capability the deviations must be below 1/3 of tolerance range.Pr

6、ocess capabilityMachine capability5Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / RESingle bladeMulti bladeComparison: Turning vs. Reamingunstablef = FeedFR = Radial ForceFRFRff6Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dullik

7、en 02/2003 Entwicklung / RE101005000.501.001.500.100.200.300.40Cutting speed vc m/minStock allowance in mmFeed rate per tooth fz mmDihart Reaming TechnologyConv. ReamingHigh Speed - ReamingHigh Performance Reaming7Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Ent

8、wicklung / REConditions for High Speed CuttingSpindleToolWorkpieceStable Machine and ToolVariable Cutting DataInner Coolant SupplyRun out of ToolExact Alignment of System8Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REInfluence of bore quality and

9、tool lifeToolGeometryTolerance rangeRun outCutting dataCoolantTool WearMaterialToolGeometryUnequal pitchRun outWorkpieceFixing of the PartAlignment Tool-PartStock AllowanceFeed rateTool WearGeometryCutting Data Cutting MaterialCoatingStock AllowanceChip Flow/ControlCoolantMaterialTool Wear/LifeMeasu

10、reForm and PositionSurface Finish9Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REFeed f mm/USurface Roughness as a Function of Feedrate and Bevel AngelRoughness Ra mASG01 45ASG02 45/8ASG04 30/410Focus Training Aluminium-Bearbeitung Dihart AG Przisi

11、onswerkzeuge Dulliken 02/2003 Entwicklung / RERoughness RaCorrect IncreasedInfluence of the Cutting SpeedBuild-up EdgeTool Cutting Edge11Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / RERoughness as a Function of Cutting Speed in using different mate

12、rialLead Alloyed Free Cutting Steel9MnSPb28Grey Cast IronGG25SteelCk45Roughness Ra umCutting Speed vc m/minConventional Reaming12Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REStructural Steel:Conventional reamingHigh Speed ReamingCutting Speed vc

13、m/minRoughness Ra mRoughness as a Function of Cutting Speed13Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / RERoughness as a Function of FeedrateFeed f mm/U2.01.51.00.500.10.51.01.52.0Roughness RaDihart High Speed ReamingConventional Reaming14Focus T

14、raining Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REclChip directionclChip directionCircular landChip flow / Chip breakASG09B15Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REInfluence of wear for reamingBore-

15、 / RoughnessWear Demanded RoughnessLower Diameter Limit16Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REDihart Cutting Material and CoatingsHMPKDDBGDSNTiNDSTDBNDJC17Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003

16、Entwicklung / REQuality of Dihart CoatingsDihart- NotationTiNDBNDBGCoating NotationTiNTiCNTiAlNMicro-hardness HV 0.05230030003300Friction Coefficient for Steeldry0.40.40.3 0.35Layer Thickness m2 - 42 - 41.5 - 3Max. Applications-temperature C600400900Layer ColorGold ColorBlue/GrayViolet/Black18Focus

17、Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / RERoughness as a Function of Cutting Speed in DSTRoughness Ra mCutting Speed vc m/min19Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / RERoughness Ra mCutting S

18、peed vc m/minRoughness as a Function of Cutting Speed in DBG-Coating20Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REMachining of Cast IronIncrease of WearSurfacequalitysmalllargebadCast Iron FerriticConv. Reaming High Speed ReamingCast Iron pearli

19、ticConv. Reaming High Speed ReamingGGVHigh Speed Reamingwithout Tiwith Tigood21Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / RERoughness as a Function of MicrostructurePearlitic Microstructure= Ra = 0,31 m= Rz = 2,50 mPearlitic/ Ferritic Microstruct

20、ure= Ra = 0,36 m= Rz = 3,40 mFerritic Microstructure= Ra = 1,53 m= Rz = 8,70 m22Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REReaming of Aluminum with 13% SiCutting Speed Vc m/minRouhgness Ra mCarbide DST TiN- coating PCD23Focus Training Aluminium

21、-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REApplication Range of PCD Reamers24Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REMachining of Alu wrought Alloy with PCDStandard Geometry ASG11Chip Flow GeometryChiparound t

22、he ToolNo Chipon theTool25Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REJob of CoolantTo lubricate the cutting edge, circular land, chip surface and clearance surface = Increasing the tool lifeTo cool the cutting edge = Increasing the abrasion of

23、the cutting edgePrevention of a Built-up edgeChip Flow26Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / RERoughness as a Function of CoolantMaterial: GG25Reamer: 340.21 20- H7 ASG01Feed constant: f = 0.80 mm/UCutting Speed Vc m/minRa m27Focus Training

24、 Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REProblem with reduced coolant for reamingCoolingTo cancel the job of coolant means problems with:LubricatingChip flowThe coolant functions must be taken over from the Tool, Workpiece, ChipEffects for the machining pr

25、ocessPart: Measurement, surface qualityFrictions and adhesion on the circular landTool temperature and cutting forcesTool wearChip forming and flowProblems by using Mist Coolant28Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REHolderTie RodIntegrate

26、d Tension nutOptimized for Mist CoolantREAMAXTM High Performance Reaming for Mist CoolantREAMAXTM replaceable insert29Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REResult in gray cast iron with REAMAXTMMachine:Hller Hille TrockenspechtWorkpiece:Se

27、itenstnder GG252 Bores with 50 mm 16 H73 Bores with 35 mm 16 H7Tool:REAMAXTM Holder 640.01.002Head 640.37 16 H7HM/ DBGASG12Cutting Data:S = 250 m/minF = 1.50 mm/U = 6000 mm/min30Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REResult:Tool life 43 min

28、250 m Tool life lengthRz Use DAH-Compensation holderTool lifem32Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REInfluence of Shape of the workpieceUnequal WallthicknessAngular Bore Entry33Focus Training Aluminium-Bearbeitung Dihart AG Przisionswerkzeuge Dulliken 02/2003 Entwicklung / REBad Entry ConditionsPilot- Reamer with ASG161. Journal reamed to finish diameter or to pre-machining diameterFinish- Reamer with ASG16:Moving slowly into 1 journal with the pre-machining st