The application of end mills in the processing of metal stamping dies

End mills are mainly used for milling planes, steps, grooves and contours in the processing of metal stamping dies. Selecting the appropriate type of end mill, optimizing cutting parameters and controlling tool vibration are crucial for processing quality and efficiency. The following is a specific analysis:

Processing parts and tool selection

Planar processing: End mills can be used to process the planar parts of molds, ensuring flatness and surface quality. In the processing of large mold bases or templates, end mills play a significant role.

Step and groove processing: End mills are also suitable for processing steps and grooves in molds, meeting the diverse requirements of mold design.

Contour processing: For the contour processing of molds, end mills can precisely control the processing shape, improving the accuracy and consistency of the molds.

Tool types and characteristics

Integral end mills: Integral end mills feature high rigidity and cutting performance, and are suitable for processing a variety of materials. In the processing of metal stamping dies, integral end mills are often used in rough and semi-finish machining stages.

Indexable end mills: The inserts of indexable end mills can be conveniently replaced, reducing tool costs. Meanwhile, indexable end mills also have high processing efficiency and precision, and are suitable for the finishing stage of metal stamping dies.

Special-shaped end mills: such as ball-end end mills, arc-end end mills, etc. These tools have special head shapes and are suitable for processing complex shapes such as curved surfaces and inclined surfaces in molds.

Cutting parameter optimization

Cutting speed: Select the cutting speed reasonably based on the material of the workpiece to be processed, the material and coating of the end mill, and other factors. 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 and width: Select the cutting depth and width reasonably based on the workpiece requirements and tool performance. Excessive cutting depth and width may lead to excessive tool wear or workpiece deformation. If the cutting depth and width are too small, it may increase the processing time and cost.

Tool Vibration and Control

Vibration cause: There is a tiny gap between the end mill cutter and the tool holder, and vibration may occur during the processing. Vibration can cause uneven depth of cut on the circumferential edge of the end mill, affecting the machining accuracy and the service life of the tool.

Control measures: To reduce tool vibration, measures such as lowering the cutting speed and feed rate, increasing the rigidity of the tool system, and enhancing the workpiece clamping force can be taken. When resonance occurs in the processing system, factors such as cutting speed, feed rate, rigidity of the tool system, workpiece clamping force, and the shape or clamping method of the workpiece should be checked, and corresponding measures should be taken for adjustment.