Optimization of cutting parameters of end mills in the processing of valve parts

In the processing of valve parts, the optimization of the cutting parameters of counter milling cutters can be approached from aspects such as the selection of tool materials and coatings, adjustment of geometric parameters, optimization of cutting parameters, and improvement of processing strategies. The following is a specific analysis:

Tool material and coating selection

Material selection: Choose the appropriate tool material for different materials. When processing materials with high hardness such as stainless steel and prone to generating sticky chips, cobalt-containing high-speed steel end mills are selected. Their heat resistance and anti-sticky chip ability are superior to those of ordinary high-speed steel tools. When processing soft materials such as aluminum alloys, carbide end mills have more advantages in terms of wear resistance and cutting efficiency.

Coating selection: Enhance tool performance through coating technology. When processing stainless steel, the use of AlCrN coating can reduce the friction and chip adhesion between the tool and the workpiece. When processing carbon fiber composite materials, diamond coating can significantly reduce tool wear and extend service life.

Optimization of tool geometric parameters

Rake Angle adjustment: Optimize the rake Angle based on the material properties. When processing aluminum alloys, a rake Angle of 10° to 15° can reduce the cutting force. When processing stainless steel, a rake Angle of 5° to 8° can enhance the strength of the tool and reduce the risk of chipping.

Helix Angle optimization: Select the helix Angle reasonably. The 30° helix Angle is suitable for processing with large feed rates and can improve processing efficiency. A 45° helix Angle is suitable for high-precision processing and can improve surface quality.

Edge number selection: Select the edge number based on the processing requirements. When rough machining, two-edge end mills are selected, as they have a large chip holding slot space and smooth chip removal. When performing finish machining, 4-edge or 6-edge end mills should be selected to reduce cutting residues and improve surface finish.

Optimization of cutting parameters

Cutting speed: Adjust the cutting speed according to the hardness of the material. When processing aluminum alloys, the cutting speed can reach 150 to 200 meters per minute. When processing stainless steel, the cutting speed needs to be reduced to 30-50m/min to control the cutting heat.

Feed rate: Select the feed rate based on the material of the cutting tool and the workpiece. When processing aluminum alloys, the feed rate can be selected as 0.1 to 0.2mm per tooth. When processing stainless steel, the feed rate should be reduced to 0.05-0.1mm per tooth to reduce the tool load.

Cutting depth: Layer-by-layer processing controls the cutting depth. Each cutting depth is controlled within 0.5 to 1mm, which can not only reduce tool vibration but also ensure processing accuracy.

Improvement of processing strategy

Layered processing: For deep grooves or complex surfaces, a layered processing strategy is adopted, with each cutting depth controlled within a reasonable range to reduce tool load and improve dimensional accuracy.

Tool path optimization: Use the row cutting method or loop cutting method to reduce idle travel and improve processing efficiency. For curved or rounded corners, a ball-end end mill is used for smoothing processing to ensure a natural transition.

Cooling and lubrication: Select the cooling method based on the processed material. When processing aluminum alloys, compressed air is used for cooling to prevent oxidation caused by residual cutting fluid. When processing stainless steel and carbon fiber composite materials, extreme pressure cutting fluid is used to reduce the cutting temperature and friction coefficient.