Application skills of end mills in the processing of musical instrument parts

In the processing of musical instrument parts, the application skills of end mills are mainly reflected in tool selection, clamping processing, optimization of cutting parameters, selection of cutting methods, and processing strategies for special requirements. The following is a specific analysis:

Tool selection

Material and coating: Select the appropriate material and coating for the end mill based on the material of the instrument parts (such as wood, metal, etc.). For instance, when processing metal parts of Musical Instruments, hard alloy end mills can be selected, and the use of TiAlN coating can be considered to enhance the wear resistance and heat resistance of the tools.

Number of cutting edges and edge profile: Select the appropriate number of cutting edges and edge profile based on processing requirements. For musical instrument parts that require high-precision processing, end mills with a larger number of edges and finer edge profiles can be selected to ensure the quality and accuracy of the machined surface.

Shape and size: Select the appropriate end mill based on the shape and size of the instrument parts. For example, when processing musical instrument parts with arcs or curved surfaces, ball-end end mills or round-nose end mills can be selected. When processing small or precise musical instrument parts, small-diameter end mills can be selected.

Clamping processing

Cleaning and drying: End mills are usually coated with anti-rust oil when leaving the factory. If non-water-soluble cutting oil is used during cutting, a layer of misty oil film will adhere to the inner hole of the tool holder, making it difficult for the tool holder to firmly hold the tool holder and causing the end mill to loosen and fall off during processing. Therefore, before clamping, the shank part of the end mill and the inner hole of the tool holder should be thoroughly cleaned with cleaning solution, dried and then clamped.

Side locking: When the diameter of the end mill is large, even if the tool holder and the tool holder are very clean, a tool drop accident may still occur. At this point, a tool holder with a flattened notch and the corresponding side locking method should be selected to ensure the stable clamping of the tool.

Cutting parameter optimization

Cutting speed: The cutting speed should be reasonably selected based on factors such as the material of the instrument parts and the material and coating of the end mill. Excessive cutting speed may lead to accelerated tool wear or a decline in the surface quality of the workpiece. If the cutting speed is too low, it may reduce the processing efficiency.

Feed rate: The selection of feed rate should comprehensively consider the material of the workpiece, the diameter of the tool and the processing requirements. Excessive feed rate may cause excessive tool load or vibration marks on the workpiece surface. A feed rate that is too slow may reduce production efficiency.

Cutting depth: Select the cutting depth reasonably based on the workpiece requirements and tool performance. Excessive cutting depth may lead to excessive tool wear or workpiece deformation. If the cutting depth is too small, it may increase processing time and cost.

Selection of cutting methods

Climb milling and reverse milling: Select the appropriate cutting method based on the processing requirements and the material of the workpiece. Climb milling is beneficial for preventing the damage of the cutting edge and improving the tool life. However, it is necessary to pay attention to eliminating the clearance of the feed mechanism and use reverse milling when there is an oxide film or hardened layer remaining on the workpiece surface.

Special processing requirements processing

Thin-walled parts processing: For thin-walled parts in musical instrument components, the processing strategy of rise milling, high-speed, small-diameter end milling, layer-by-layer milling, and small side depth of cut should be adopted to reduce the back force, minimize deformation, and improve the flatness and dimensional accuracy of the side surface.

Surface machining: For the curved parts of musical instrument components, ball-end end mills can be used for processing, and the quality and accuracy of the machined surface can be ensured by controlling the tool path and cutting parameters.