Dihart铰刀培训ppt课件

1、Technology of reaming.Fine tooling of boresDefinitionFine tooling of bores is every kind ofCuttingForming WashMachining to get ISO IT quality of a bore with IT 9 or better. Methods for Micro Finishing of Bores CuttingFormingWashGeometrically determined cutting shape (Tool cutting edge)Geometrically

2、not determined cutting shape (Cutting grain)Single blade toolMultiple blade toolBonded grainLoosegrainPress-polishingInternal superfinish turningFineboringReamingGrindingHoningPolish grindingLappingVibration lappingPolish lappingCalibratingBrunishingErodePolish engraveElectrolytic machining Polish e

3、lectrolytic.Range 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 Tole

4、rances.Process- 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.Process capabilityMachine capability.Single bladeMulti bladeComparison: Turning vs. Reamingunstable

5、f = FeedFR = Radial ForceFRFRff.101005000.501.001.5000.40Cutting speed vc m/minStock allowance in mmFeed rate per tooth fz mmDihart Reaming TechnologyConv. ReamingHigh Speed - ReamingHigh Performance Reaming.Conditions for High Speed CuttingSpindleToolWorkpieceStable Machine and ToolVaria

6、ble Cutting DataInner Coolant SupplyRun out of ToolExact Alignment of System.Influence of bore quality and tool lifeToolGeometryTolerance rangeRun outCutting dataCoolantTool WearMaterialToolGeometryUnequal pitchRun outWorkpieceFixing of the PartAlignment Tool-PartStock AllowanceFeed rateTool WearGeo

7、metryCutting Data Cutting MaterialCoatingStock AllowanceChip Flow/ControlCoolantMaterialTool Wear/LifeMeasureForm and PositionSurface Finish.Feed f mm/USurface Roughness as a Function of Feedrate and Bevel AngelRoughness Ra mASG01 45ASG02 45/8ASG04 30/4.Roughness RaCorrect IncreasedInfluence of the

8、Cutting SpeedBuild-up EdgeTool Cutting Edge.Roughness as a Function of Cutting Speed in using different materialLead Alloyed Free Cutting Steel9MnSPb28Grey Cast IronGG25SteelCk45Roughness Ra umCutting Speed vc m/minConventional Reaming.Structural Steel:Conventional reamingHigh Speed ReamingCutting S

9、peed vc m/minRoughness Ra mRoughness as a Function of Cutting Speed.Roughness as a Function of FeedrateFeed f mm/U2.01.51.00.501.52.0Roughness RaDihart High Speed ReamingConventional Reaming.clChip directionclChip directionCircular landChip flow / Chip breakASG09B.Influence of wear for ream

10、ingBore- / RoughnessWear Demanded RoughnessLower Diameter Limit.Dihart Cutting Material and CoatingsHMPKDDBGDSNTiNDSTDBNDJC.Quality of Dihart CoatingsDihart- NotationTiNDBNDBGCoating NotationTiNTiCNTiAlNMicro-hardness HV 0.05230030003300Friction Coefficient for Steeldry 0.35Layer Thickness

11、m2 - 42 - 41.5 - 3Max. Applications-temperature C600400900Layer ColorGold ColorBlue/GrayViolet/Black.Roughness as a Function of Cutting Speed in DSTRoughness Ra mCutting Speed vc m/min.Roughness Ra mCutting Speed vc m/minRoughness as a Function of Cutting Speed in DBG-Coating.Machining of Cast IronI

12、ncrease of WearSurfacequalitysmalllargebadCast Iron FerriticConv. Reaming High Speed ReamingCast Iron pearliticConv. Reaming High Speed ReamingGGVHigh Speed Reamingwithout Tiwith Tigood.Roughness as a Function of MicrostructurePearlitic Microstructure= Ra = 0,31 m= Rz = 2,50 mPearlitic/ Ferritic Mic

13、rostructure= Ra = 0,36 m= Rz = 3,40 mFerritic Microstructure= Ra = 1,53 m= Rz = 8,70 m.Reaming of Aluminum with 13% SiCutting Speed Vc m/minRouhgness Ra mCarbide DST TiN- coating PCD.Application Range of PCD Reamers.Machining of Alu wrought Alloy with PCDStandard Geometry ASG11Chip Flow GeometryChip

14、around the ToolNo Chipon theTool.Job 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 the cutting edgePrevention of a Built-up edgeChip Flow.Roughness as a Function of CoolantMat

15、erial: GG25Reamer: 340.21 20- H7 ASG01Feed constant: f = 0.80 mm/UCutting Speed Vc m/minRa m.Problem 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 mach

16、ining processPart: Measurement, surface qualityFrictions and adhesion on the circular landTool temperature and cutting forcesTool wearChip forming and flowProblems by using Mist Coolant.HolderTie RodIntegrated Tension nutOptimized for Mist CoolantREAMAXTM High Performance Reaming for Mist CoolantREA

17、MAXTM replaceable insert.Result in gray cast iron with REAMAXTMMachine:Hller Hille TrockenspechtWorkpiece:Seitenstnder 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/min.Result:Tool lif

18、e 43 min250 m Tool life lengthRz Use DAH-Compensation holderTool lifem.Influence of Shape of the workpieceUnequal WallthicknessAngular Bore Entry.Bad 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 step.Increase speed and machine all journalsFront of 1. journalDifficult EntryStock allowance = 2.60 mmCam bore machining.Fixation or clamping of workpiece.Clamping with 8 NmZyl.-Form 10.30mClamping 6 NmZyl.-Form 5.45mInfluence of clamping device.The way from t