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The end mill is widely used in the plastic processing of the toy manufacturing industry, and its efficient and precise processing ability makes it a key tool for plastic mold manufacturing. From application characteristics, technical details to challenge solutions, the following is a comprehensive analysis for you:
First, the core application of end milling cutter in plastic processing
High efficiency precision machining
The end mill, combined with high-speed milling technology (spindle speed 3000-5000rpm), achieves high surface finish through light cutting method (cutting depth 0.02-0.1mm), especially suitable for small and medium-sized precision plastic molds (such as toy shells, complex structural parts). Compared with the traditional process, it can shorten the manual polishing time by 60%-100% and reduce the EDM process.
Ability to process complex structures
Thin wall and reinforcement: the low cutting force of high-speed milling can process thin walls above 0.1mm to solve the problem of small rounded corners and root clearing.
High hardness materials: PCD coated tools support HRC64 and above die steel processing, improve wear resistance.
Multi-function tool selection
Material: high speed steel or carbide end mill, carbide is more suitable for high hardness materials.
Type: Ball end mill for surface finishing, flat end cutter for contour accuracy.
Second, plastic processing technical details
Optimization of tool geometry parameters
Front Angle: 15°-25°, reduce cutting force; Back Angle: 15°-18°, reduce friction; Spiral Angle: 20°-25°, control chip removal direction.
Chip tank design: Large chip tank avoids chip blocking, O-shaped cutter groove optimizes soft plastic chip flow, and flat front cutter surface design ADAPTS to hard plastic.
Cutting parameter adjustment
Speed: Increase the cutting speed (to avoid exceeding the softening point of the material), such as higher VC efficiency.
Feed: Roughing 1-5mm per cutter, finishing with ball end milling cutter, speed 2500-3500mm/min.
Cooling: Water cooling prevents plastic softening (such as nylon softening point 180-220 ° C), and the coolant flow is sufficient.
Clamping and vibration control
Clamping technology: clamping plate or special fixture firmly fixed to avoid deformation.
Anti-vibration measures: Adjust cutting parameters (such as reducing speed by 40%) or replace anti-vibration tools to reduce the impact of vibration on accuracy.
Third, processing challenges and solutions
Tool wear and life
Soft plastics: Large front Angle tool to reduce wear, but need to control the back Angle (too large easy to flutter, too small friction heating).
Hard plastic: moderate front Angle and flat back Angle design to avoid “crescent” phenomenon.
Enhanced plastic: balance the front Angle and the back Angle, match the spindle speed and feed rate, prevent the edge from falling.
Vibration and deformation control
Thin-walled parts: high-speed milling reduces cutting force, multi-point light pressure when clamping.
Tool vibration: Adjust the cutting parameters or replace the anti-vibration tool (such as changing the core thick groove design).
Chip and chip removal problems
Soft plastics: O-shaped slots optimize chip flow and prevent blocking.
Hard plastic: multi-slot spiral blade cutter improves chip removal efficiency and avoids secondary chip damage.
Fourth, typical cases and innovation direction
High-speed milling applications: Significantly improve the surface quality of plastic molds and shorten the lead time through light cutting and close tooling.
PCD coated tools: Reduce wear in graphite electrode machining and achieve efficient discharge machining.
Through the above technology, the end mill achieves the balance of precision, efficiency and cost in the plastic processing of toy manufacturing, and promotes the manufacturing upgrade of complex toy molds.
