The application of end mills in the Processing of Sanitary Ware parts

End mills are widely used in the processing of bathroom fixture parts. The following is an analysis from aspects such as tool selection, cutting parameter setting, processing strategy optimization, and special process treatment:

Tool selection and material matching

Material compatibility: For the commonly used aluminum alloy, stainless steel and plastic materials in bathroom fixtures, the corresponding tool materials should be selected. When processing aluminum alloys, high-speed steel end mills are recommended as their heat resistance meets the cutting requirements. When processing stainless steel, hard alloy end mills need to be adopted to meet the cutting challenges of high-hardness materials. In plastic processing, hard alloy tools with special coatings can be selected to reduce material adhesion.

Tool type selection: Select the type of end mill cutter based on the processing characteristics. For planar processing, flat-bottomed end mills are recommended. Their end face cutting edges can efficiently complete planar milling. Surface processing is applicable to ball-end end mills, and precise processing of three-dimensional surfaces is achieved through ball-end design. For slot processing, keyway end mills should be selected, as their special structure can ensure the dimensional accuracy of the slot shape.

Cutting parameter optimization strategy

Spindle speed setting: Determine the speed range based on the material properties. The processing speed of aluminum alloy can be set at 150-200m/min, while that of stainless steel needs to be reduced to 50-100m/min. By adjusting the speed, the tool life and processing efficiency can be balanced.

Feed rate control: Adjust the feed rate in combination with the tool diameter and the workpiece material. The feed rate for aluminum alloy processing is recommended to be 0.1-0.2mm per tooth, while for stainless steel processing, it should be controlled at 0.05-0.1mm per tooth. Parameter adjustment should take into account the matching of 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.

Processing strategy and process optimization

Vibration suppression technology: Reducing the impact of vibration through parameter adjustment. When tool vibration occurs, the cutting speed and feed rate should be reduced first (the reduction is recommended to be within 40%). If the vibration persists, the cutting depth should be reduced. If necessary, the tool overhang support device can be added.

Cooling and lubrication scheme: Select cooling methods for different materials. For aluminum alloy processing, compressed air cooling is recommended. For stainless steel processing, extreme pressure cutting fluid should be used. By optimizing the cooling method, the cutting temperature can be reduced and tool wear can be decreased.

Improvement of the clamping system: For large-diameter end mills, a tool holder with a flattened notch can be used in combination with a side locking device. Regularly check the wear of the tool holder (it is recommended to inspect once every 500 pieces processed) to ensure the rigidity of the clamping system.

Key points of special process treatment

Thin-walled part processing: By adopting a parameter combination of small cutting depth, high rotational speed and low feed rate, and in combination with vacuum adsorption clamping method, the cutting force is reduced to avoid workpiece deformation.

Surface finishing: Use a ball-end end mill in combination with contour line processing paths. Achieve a mirror-like effect by controlling the residual height (recommended ≤0.01mm). After processing, polishing treatment is required to eliminate tool marks.

Micro-feature processing: Select micro end mills with a diameter of ≤1mm, adopt high-speed cutting (linear speed ≥80m/min) and micro-lubrication technology, and monitor the tool wear state in real time through a CCD vision system.