Cutting strategies of end mills in the processing of door lock parts

In the processing of door lock parts, the cutting strategy of end mills needs to comprehensively consider tool selection, cutting parameters, clamping methods and processing path planning. The following is a specific analysis:

Tool selection:

Material selection: Common materials for door lock parts include aluminum alloy, stainless steel and zinc alloy, etc. For aluminum alloy materials, high-speed steel end mills can be selected. For materials with higher hardness such as stainless steel and zinc alloy, it is recommended to use carbide end mills to enhance wear resistance and cutting efficiency.

Tool type selection: According to the processing characteristics, flat-bottom end mills can be used for planar processing. Ball-end mills are selected for surface processing. For the processing of keyways or grooves in door locks, keyway end mills should be selected to ensure the dimensional accuracy of the groove shape.

Cutting parameter optimization

Spindle speed setting: For aluminum alloy processing, the recommended speed is 150-200m/min. For stainless steel or zinc alloy processing, the speed should be reduced to 50-100m/min to balance tool life and processing efficiency.

Feed rate control: For aluminum alloy processing, the feed rate is recommended to be 0.1-0.2mm per tooth. For stainless steel or zinc alloy processing, it should be controlled at 0.05-0.1mm per tooth. The specific parameters need to be adjusted in combination with the tool diameter and workpiece hardness.

Cutting depth management: In the rough machining stage, the single cutting depth is recommended not to exceed 50% of the tool diameter. In the finish machining stage, it should be controlled within the margin range of 0.05-0.1mm. Dimensional accuracy is guaranteed through a layer-by-layer processing strategy.

Improvement of the clamping system

Clamping method: When using a spring clamp set to clamp end mills, it is necessary to ensure that the tool holder and the inner hole of the tool clamp are clean to avoid insufficient clamping force caused by oil film. For large-diameter end mills, it is recommended to choose a shank with a flattened notch and a side locking method to enhance the clamping rigidity.

Tool holder maintenance: Regularly inspect the wear condition of the tool holder. If the end of the tool holder is found to be worn into a conical shape, a new tool holder should be replaced in time to prevent the neutral milling cutter from breaking at the end of the tool holder during processing.

Processing path planning

Layered processing strategy: For the processing of deeper grooves or cavities, a layered processing strategy is adopted to reduce the tool extension and lower the risk of tool deflection deformation.

Vibration suppression technology: If tool vibration occurs during the processing, the cutting speed and feed rate can be appropriately reduced (the reduction is recommended to be within 40%). If the vibration persists, the cutting depth needs to be reduced, and if necessary, a tool overhang support device should be added.

Cooling and lubrication scheme:

Cooling method selection: For aluminum alloy processing, compressed air cooling is recommended. For stainless steel or zinc alloy processing, extreme pressure cutting fluid should be used to lower the cutting temperature, reduce tool wear, and improve chip discharge.