Vous êtes sur la page 1sur 55

CNC Tooling

Computer numerical control tooling


presentation:-
Prepared by:-
ØShyam Kumar sonu.
ØRahul Raman.
ØBijay Kumar shah.
Ømd .Sallaudin .
ØDurga nand chaudhary.
ØBinoy tamang.
cnc tooling Group 2(DMCH 2007) 1
Introduction
•CNC
tooling
cnc tooling Group 2(DMCH 2007) 2
Topic contents
q Cutting tool material.
q Tooling for hole operation.
q Types of drilling process.
q Milling cutters.
q Types of milling cutters.
q Special inserted cutters.
q Types of inserted cutters &selection.
q Identification system and grading system.
q Cutting speed and feeds.
q Milling & drilling feed rates.

cnc tooling Group 2(DMCH 2007) 3


Properties of tool material
Ø Toughness
Ø Wear resistance.
Ø Hot hardness.
Ø Recovery hardness.
Ø Thermal conductivity.
Ø co-efficient of thermal expansion.
Ø Hardenability .
Ø Weldability.
Ø Grindability .
Ø Dimension stability.
cnc tooling Group 2(DMCH 2007) 4
Tooling For CNC
Cutting tool Materials
Cutting tools are available in three
basic types
Cutting tool
material

High speed TUNGUSTEN


carbide Ceramic
steel

cnc tooling Group 2(DMCH 2007) 5


Tooling For CNC
High speed steel(HSS)
•HSS tool have the following advantages
over carbide
•HSS cost less than carbide and ceramic tooling.
•HSS is less brittle and not as likely to break to
during interrupted cuts .
•The tool can resharpened easily.
•HSS tool having following
disadvantage
•HSS does not hold up as well as carbide or
ceramic at high cnc
temperature generated during
tooling Group 2(DMCH 2007) 6
Tooling for cnc

Tungsten carbide
(carbide)
• Carbide tools come in one of
three types.
Carbide tools

Solid Inserted
Brazed
carbide carbide
carbide tools
tools tooling
cnc tooling Group 2(DMCH 2007) 7
Tooling for cnc
ØTungsten carbide.
• Solid carbide tools are made from a solid piece of
carbide.
• Brazed carbide tools use a carbide tip brazed in a steel
shank.
• Inserted carbide tooling utilize indexable inserts made
of carbide which are held in steel tool holders.
Ø Tungsten carbide has the following
advantages over HSS.
• Carbide holds well up at elevated temperatures.
• Carbide can cut hard materials well.
• Solid carbide tools absorb workpiece vibrations and
reduce the amount of “chatter” generated during
machining.
cnc tooling Group 2(DMCH 2007) 8
• When inserted cutters are used the inserts can be
Tooling for numerical
control
ØTungsten carbide
Tungsten carbide has the following
disadvantage over HSS.
• Carbide cost more than high speed
steel tools.
• Carbide is more brittle than HSS and
had a tendency to chip during
interrupted cuts.
• Carbide is harder to resharpen and
requires diamond grinding wheels.
cnc tooling Group 2(DMCH 2007) 9
Tooling for numerical
control
ØCeramic tooling
• Had made great advances in the past several years.
• Once very expensive-some ceramic insert cost now
less than carbide.
Ceramic has the following advantage:
• Ceramic is sometime less expensive than carbide
when used in insert tooling.
• Ceramic will cut harder materials at a faster rate.
• Ceramic has superior heat hardness.
Ceramic has the following disadvantages:
• Ceramic is more brittle than HSS or carbide.
• Ceramic must run within its given surface speed
parameters.
Notes :- If run too cnc
slowly, the
tooling Group inserts
2(DMCH 2007) will breakdown
10
Tooling for numerical
control
ØFields of application.
High speed steels used on:-
• Aluminium alloys.
Carbide is used on:-
• High silicon aluminium.
• Steels .
• Stainless steels.
• Exotic metals.
Ceramics inserts used on:-
• Hard steels.
• Exotics metals.
Notes :-Inserted carbide tooling is becoming the
preferred for any cnc application.
Notes :-some insert carbide are coated with special
substances(e.g. Titanium nitride) increasing tool life
up to 20 time –using recommended cutting speed and
feed rates. cnc tooling Group 2(DMCH 2007) 11
Tooling for hole operation
ØTooling for hole operations.
• There are four basic hole operations that are
performed on nc machinery.
Tooling for hole
operations.

Drilling Reaming Boring tapping

cnc tooling Group 2(DMCH 2007) 12


TOOLING for hole operation

cnc tooling Group 2(DMCH 2007) 13


Tooling for hole operations
ØDrilling
• Drills are available in different styles for
different materials.
• Twist drills remains one of the most common
tools for making holes.
• Drills have a tendency to walk as drill, resulting
in a hole that it is not truly straight.
• Centre drills are often used to predrilled a pilot
hole to help twist drill to start straight.
• Drills also produce triangular shaped holes.

cnc tooling Group 2(DMCH 2007) 14


Tooling for hole operations
ØDrilling
• If the hole tolerance is closer than 0.003 inch a
secondary hole operation should to use to size
the hole such as boring or reaming.
• Large holes are sometimes produced by spade
drills.
• The flat blade in spade drills allow good chip flow
and economical replacement of the drill tip.

cnc tooling Group 2(DMCH 2007) 15


Tooling for hole operations
• Drill point angle must be considered when selecting a
drill.
• The harder the material to be cut the greater the drill
point angle needs to be maintain satisfactory tool life.
• Mild steel is usually cut with a 118-degree included
angle drill point.
• Stainless steel often use 135- degree drill point.
ØTypes of drills:-
• HSS drills are the most common.
• Brazed carbide and solid carbide.
• Carbide drill chip when drilling holes.
• When drilling hard materials cobalt drills are used(HSS
with cobalt). cnc tooling Group 2(DMCH 2007) 16
Tooling for hole operations
ØReaming :-
• Reaming is used to remove a small amount of
metal from an existing hole as a finish operation.
• Reaming is a precision operation which will hold
a tolerance of +\-0.0002 inch easily.
• Straight fluted reamers.

cnc tooling Group 2(DMCH 2007) 17


Tooling for hole operation
ØReaming :-
• Spiral fluted reamers
• Spiral fluted reamers produce better surface
finishes than straight flutes.
• Spiral flutes reamers are more difficult to
resharpen than straight fluted.
• Reamers are available in three basic tool
materials:
ü HSS
ü Brazed carbide
ü Solid carbide.

cnc tooling Group 2(DMCH 2007) 18


Tooling for hole operations
ØBoring :-
• Boring removes metal from an existing hole with
a single point boring bar.
§ Boring heads are available in two designs.
• Offset in which the boring bar is a separate tool
inserted into the head .
• Cartridge which use an adjustable insert in place
of a boring bar.
§ Boring bars are available in four material
types:-
• High speed steels (HSS)
• Solid carbide –upcncto ½-inch diameter.
tooling Group 2(DMCH 2007) 19
Tooling for hole operations
ØTapping:-
• Tapping is used to produce internally threaded
holes
They are available in different flute design:-
• Standard machine screw taps are widely used
when tapping blind holes .
• Spiral pointed taps (gun taps)which are preferred
for thru- hole operations- shoot chip forward and
out of the bottom of the hole .
• High spiral taps are used for soft stringy material
(e g aluminium).

cnc tooling Group 2(DMCH 2007) 20


Milling cutters
The rotating cutter, termed
the milling cutter, has almost
an unlimited variety of
shapes and sizes for milling
regular and irregular forms.
The most common milling
cutter is the end mill. Other
tools that are often used are
shell mills, face mills, and
roughing mills. When milling,
care must be taken not to
take a cut that is deeper than
the milling cutter can handle.
End mills come in various
shapes and sizes, each
designed to perform a
cnc tooling Group 2(DMCH 2007) 21
Milling cutters
Ø Milling cutters can be further
classified as:-

Milling
cutters

End Face
mills mills

cnc tooling Group 2(DMCH 2007) 22


Milling cutters
ØThread hob:-
• A special milling cutter is used to mill a thread in
a workpiece.
• Thread hobs make use of an NC machines helical
interpolation capabilities.

cnc tooling Group 2(DMCH 2007) 23


Milling cutters
Ø End mills:-
End mills are available in :
q High speed steels (HSS)
q Solid carbide
End mills are available in diameters:-
q From 0.032 inch to 0.500 inch.
Inserted end mills:-
q From 0.500 inch to 3 inch.
q Note 1:-two flute cutters with deeper gullets are well
suited for roughing operations.
q Note 2:-four flute end mills are more rigid because their
rigid core.

cnc tooling Group 2(DMCH 2007) 24


Pictures of end mill cutter

Single end multiple flute end


mill

Solid carbide two flute end


mill

Ball nose end mill


cnc tooling Group 2(DMCH 2007) 25
Milling cutters
End mills:-
•Inserted cutters are preferred for NC
application.
•Inserts are less expensive to replace
than an entire tool.
•By indexing the inserts four or six
cutting edges can be used on one
inserts.
•When the insert is used up it is thrown
away rather than resharpened.
•Inserted cutter may used on many
type of workpiece materials by
changing the inserts from one
designed for aluminium to2(DMCH
cnc tooling Group one2007) 26
Pictures of end mill cutter

cnc tooling Group 2(DMCH 2007) 27


Milling cutters

End mill:-
•Ball end mills using inserts.
•Ball end mills are also available in
HSS and solid carbide.
•Ball mills are used for three ,four or
five –axis contouring work where z
axis is used.
•They are also used to produce a

cnc tooling Group 2(DMCH 2007) 28


Milling cutters
End mills:-
ØInserted end mill
(cyclo mill).
•Cyclo mill uses a
series of round
inserts staggered
on a helical
pattern.
•Cyclo mill was
develop for NC
cnc tooling Group 2(DMCH 2007) 29
Milling cutters
ØFace mills:-
• face mills are designed to remove large amounts
of material from the face of the workpiece.
• Face mills are manufacture in :
§ High speed steel(HSS)
§ Brazed carbide
§ Inserted carbide(the most common type of facing
tool)
• Face mills are available in two sizes: from 2 inch
to over 8 inch in diameter.
• Note 1:-The cost of HSS and brazed carbide limit their
application to special situation.
cnc tooling Group 2(DMCH 2007) 30
Face mill cutters

cnc tooling Group 2(DMCH 2007) 31


Milling cutters

Face mills:-
qLarge
diameter
face mill
qLarge
number of
insert used.
qCyclo mill
was

cnc tooling Group 2(DMCH 2007) 32


Milling cutters
Ø Face mills:-
• Plunge and
profile cutter.
• It is designed to
plunge into the
material first and
then begging the
cutting path.
• The design is a
cross between end
mill and face mill.
cnc tooling Group 2(DMCH 2007) 33
Special inserted cutters
• Special inserted cutters:-
• A number of special tools have been
developed for use with CNC.
• The NC programmer is always
confronted with new ideas to
improve productivity.
• Prospective and experienced
programmers should spent time
looking at tooling catalogs to
become acquainted with current
cnc tooling Group 2(DMCH 2007) 34
Special inserted cutters

cnc tooling Group 2(DMCH 2007) 35


INSERTED TOOLS

cnc tooling Group 2(DMCH 2007) 36


Examples

cnc tooling Group 2(DMCH 2007) 37


Special inserted cutters
• An inserted milling cutter with
interchangeable tooling extensions.
• A machine tap in a tap holder with
interchangeable tooling extensions.
• An inserted tool mounted in a holder with
interchangeable extensions.
Ø An NC tooling system featuring:-
• Tool adapters
• Interchangeable extensions.
• Tool bodies.
• Boring heads.
• Arbors.
cnc tooling Group 2(DMCH 2007) 38
Special inserted cutters
• Carbide inserts and their
selection:
• Carbide inserts are manufactured in a variety of
types and grades.
• The type of the insert describes the shape of the
Common
insert. inserts
shapes

Triangula 80 degree 55 degree Round


r diamond diamond

cnc tooling Group 2(DMCH 2007) 39


Special inserted cutters
Ø Carbide inserts and their selection:-
• The grade of insert describes the
hardness of the inserts and the
application of which it was developed.

• Each type of inserts identified by a


designation code.

• The identification system used on an


insert will vary depending on the
manufacture. cnc tooling Group 2(DMCH 2007) 40
Special inserted cutters
• Identification system:-
Toleran Edge
Prefix shape Radius &
ce Size conditi
chamfer
on

W R 15 S R C 6 3 H 4 T R

Clearance Thicknes Chamfe


Type Hand
s r size
cnc tooling Group 2(DMCH 2007) 41
Speed &feeds
• Feed Rate – Inches per minute (IPM)

• Spindle Speed – (RPM)

• The relationship between these 2


variables is critical to achieving
optimal tool life

cnc tooling Group 2(DMCH 2007) 42


Basic rule

Make chips NOT dust!!

Larger chip loads


=
less heat generation
=
longer tool life

cnc tooling Group 2(DMCH 2007) 43


Factors effecting feed rates
• Hold Down (part movement)
• Depth of Cut
• Material Density
• Tool Design (up shear / downs hear)
• # of flutes and geometry of flute
• Tool Balance + centricity

cnc tooling Group 2(DMCH 2007) 44


The amount of feed depends:-
• Material being cut.(hard and soft)
• Rigidity of job and machine.
• Depth of cut.
• Power available.
• Range of feed available.

cnc tooling Group 2(DMCH 2007) 45


Steps to finding “optimal” feed
rate
1) Assess hold down and machine
capabilities

2) Select tool(s) for material and


application

3) Decide on depth of cut and no of


passes

4) Start at lowest recommended feed


cnc tooling Group 2(DMCH 2007) 46
Maximum rpm.
§ Base on diameter to tool:

¼” & under – 22 000


¼’’ to 1’’ – 18 000
1” to 2” – 16 000
2’’ to 3.5’’ – 14 000
3.5’’ to 5” – 12 000

cnc tooling Group 2(DMCH 2007) 47


Important Formulas

Chip Load = Feed Rate / (RPM x # of


Cutting edges)

Feed Rate = RPM x # Cutting Edges x


chip load

Speed (RPM) = Feed Rate / (# of


cutting edges x chip load)

cnc tooling Group 2(DMCH 2007) 48


Chip Load Ranges by Material

• Chip Load = Feed Rate / (RPM x # of cutting


edges)

• SOLID WOOD
• .008 to .025 inch

• MDF / Particle Core


• .012 to .030 inch

• PLYWOOD
• .010 TO .025 inch

• PLASTICS
• .005 to .015 inch

• CARBON FIBRE cnc tooling Group 2(DMCH 2007) 49


Ways to Improve Tool Life
• Make Chips NOT dust!!
• Use highest possible feed rates
• change collets regularly
• Consider hogging + finish pass tools
Use DIAMOND tooling!!

cnc tooling Group 2(DMCH 2007) 50


Speed and feed
• Cutting speed:-
• The spindle rpm necessary to
achieve a given cutting speed can be
calculated by the formula:
rpm =CS *12\D
*3.1416
Where CS=cutting speed in surface
feet per minute.
D=diameter in inches of the
tool cnc tooling Group 2(DMCH 2007) 51
Speed and feed
• Cutting speed:-
The cutting speed of a particular tool can be
determined from the rpm ,using the formula:-
CS=D*3.14*rpm\12
On the shop floor ,the formula are often simplified . The following
formulas will yield results similar to the formulas just given.
Rpm=CS*4\d or CS=rpm*d\4
Several factors which include:-
1 . The kind of material to be machined.
2. The cutting tool material.
3. The quantity of the surface finish.
4. The efficient use of cutting fluid .
5. The method of the holding of work.
cnc tooling Group 2(DMCH 2007) 52
Speed and feeds
• Drilling feed rates:-for machining
centre use ,the feed rates given in
the table will have to be converted
to Ipm values . To accomplish this
the following formula is used:-
IPM=RPM *IPR
where; IPM= the required feed rate
inches per min.
RPM= the programmed
spindle speed revolution per min.
cnc tooling Group 2(DMCH 2007) 53
Speed and feed rates
• Milling feed rates:-
To calculate the feed rates for
milling cut,the following formula
is used:-
F=R*T*RPM
Where; F= the milling feed rate
expressed in inches per minute .
R=the chip load per
tooth.
cnc tooling Group 2(DMCH 2007) 54
Thank
you.......
cnc tooling Group 2(DMCH 2007) 55

Vous aimerez peut-être aussi