The application of end mills in the Processing of Electronic component casings

End mills have significant application value in the processing of electronic component casings, and their cutting parameters and tool selection directly affect the processing accuracy and efficiency. The following is the specific analysis:

Processing characteristics and tool selection

The enclosures of electronic components usually adopt high-precision and thin-walled structures. During processing, both surface quality and dimensional accuracy need to be taken into account. The combined design of the cylindrical cutting edge and the end cutting edge of the end mill enables it to efficiently complete the processing of planes, step surfaces and complex curved surfaces. For thin-walled structures, it is recommended to use fine-toothed end mills (with 5 to 8 teeth), as their chip-holding grooves have a larger arc radius, which can effectively reduce the risk of chip blockage. For surface processing, ball-end end mills can achieve smooth transitions by adjusting the tool path, while fillet end mills can take into account both surface processing and contour fillet requirements.

Cutting parameter optimization

In the processing of electronic component casings, the cutting parameters need to be dynamically adjusted according to the material properties. For instance, when processing carbon fiber composite materials, the cutting speed can reach 120m/min without burr defects, which is attributed to the nano-coating technology of hard alloy end mills. For soft materials such as aluminum alloys, the feed rate can be appropriately increased (such as 1500mm/min) to improve efficiency; When processing difficult-to-machine materials such as titanium alloys, the cutting speed needs to be reduced to 30-45m/min, and extreme pressure cutting fluid should be used in combination to reduce cutting heat. In addition, the axial cutting depth (ap) is usually controlled at 0.5 to 2mm, and the radial cutting depth (ae) is 30% to 50% of the tool diameter to ensure processing stability.

Process advantages and application scenarios

The core advantages of end mills in the processing of electronic component casings lie in their high precision and high flexibility. Through numerical control programming, the automatic processing of complex 3D surfaces can be achieved, such as the edge line contour processing of digital camera casings. During the roughing stage, the use of large-diameter end mills (such as φ10mm) in combination with high-speed cutting (at a speed of 1800r/min) can quickly remove the allowance. During the finishing stage, a small-diameter ball-end milling cutter (such as φ8mm) is used instead, with a 0.3mm allowance for overall area processing to ensure that the surface roughness meets the standards. In addition, the modular design of end mills (such as indexable types) can significantly reduce the cost of tool replacement and is suitable for small-batch and multi-variety production modes.