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The plunge milling method is ideal for roughing of mold cavities and is recommended for efficient machining of aerospace components. One of the special applications is to insert and mill turbine blades on a three- or four-axis milling machine, which is usually done on a dedicated machine. When the turbine blade is inserted and milled, it can be milled from the top of the workpiece down to the root of the workpiece. Through the simple translation of the XY plane, extremely complex surface geometry can be machined. When inserting and milling, the cutting edge of the milling cutter is made up of the contours of the blades. The depth of the milling can reach 250mm without tremor or distortion. The cutting direction of the tool relative to the workpiece can be downward or Up, but generally cutting down is more common. When the milling bevel is inserted, the plunge cutter moves in a combined motion along the Z-axis and the X-axis.
In some machining applications, spherical milling cutters, face milling cutters or other milling cutters can also be used for milling, milling, milling, milling and other machining. Special plunge cutters are mainly used for roughing or semi-finishing. They can be cut into the workpiece recess or cut along the edge of the workpiece, or they can be milled into complex geometries, including root cutting. To ensure a constant cutting temperature, all shank plungers are internally cooled. The body and insert of the plunge cutter are designed to cut into the workpiece at an optimum angle. Typically, the plunge cutter has a cutting edge angle of 87° or 90° and a feed rate range of 0.08 to 0.25 mm/tooth. The number of inserts on each plunge cutter depends on the diameter of the cutter. For example, a cutter with a diameter of φ20 mm is used to install two inserts, and a cutter with a diameter of f125 mm can be installed with eight inserts.
In order to determine whether the machining of a certain workpiece is suitable for the plunge milling method, the requirements of the machining task and the characteristics of the machine tool used should be considered. If the machining task requires a high metal removal rate, the use of the plunge milling method can significantly reduce the machining time. Another suitable case for the plunge milling method is when the machining task requires a large axial length of the tool (such as milling a large cavity or a deep groove), and the cutting force can effectively reduce the radial cutting force, so the side Compared with milling, it has higher processing stability. In addition, when the part of the workpiece that needs to be cut is difficult to reach by conventional milling methods, the plunge milling method can also be considered. Since the plunge cutter can cut the metal upwards, complex geometries can be milled.
From the point of view of machine suitability, if the power of the machine tool used is limited, the plunge milling method can be considered. This is because the power required for plunge milling is smaller than that of spiral milling, which makes it possible to obtain an older machine or a machine with insufficient power. High processing efficiency. For example, a 40-stage machine can be used to machine deep grooved inserts, and such machines are not suitable for long-edge spiral milling cutters because of the large radial cutting forces generated by spiral milling. The milling cutter trembles. Due to the low radial cutting force during plunge milling, it is ideal for use in older machine tools where the spindle bearings are worn. The plunge milling method is mainly used for roughing or semi-finishing. A small amount of axial deviation caused by machine shaft wear will not have a great influence on the machining quality.
As a new type of CNC machining method, the plunge milling method puts forward new requirements for CNC machining software. At present, there is still a lot of work to be done on the development of applicable software. Software vendors are working on adapting or reprogramming processing software that can handle a large number of Z-axis codes. This software must be highly flexible to accommodate a variety of different processing tasks. .
Whether for large metal machining (common in mold machining) or for machining of aerospace parts with complex geometries, the plunge milling method is a preferred tooling. Compared with the conventional processing method, the plunge milling method has high processing efficiency, short processing time, and can be applied to various processing environments. It is suitable for single-piece small-volume one-time prototype parts processing, and is also suitable for mass production of parts. A highly promising processing technology.
The characteristics and application of the plunge milling method
Plunge milling, also known as Z-axis milling, is one of the most effective machining methods for achieving high resection rate metal cutting. For the machining of curved surfaces, grooving, and machining with large tool overhangs, the machining efficiency of the plunge milling method is much higher than that of the conventional end face milling method. In fact, when it is necessary to quickly remove a large amount of metal material, the use of the plunge milling method can reduce the processing time by more than half. In addition, the plunge milling has the following advantages: 1 can reduce the deformation of the workpiece; 2 can reduce the radial cutting force acting on the milling machine, which means that the worn shaft of the shafting can still be used for plunge milling without affecting the workpiece machining. Quality; 3 tool suspension elongation is large, which is very beneficial for the milling of the workpiece groove or surface; 4 can achieve the grooving of high temperature alloy materials (such as Inconel).