干式切削.docx
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干式切削
典型干式加工
机架
材料:
St37K(DIN174FL50x40)加工设备:
TRAUBTNA300
速度:
50-5,000rpm
冷却润滑剂:
以前(wet):
乳化液
现在(MQL)准干式润滑剂
湿加工干式加工
n
切削速度
Feed
Cuttingspeed
Feed
Tools
Vc[m/min]
f[mm/rev]Tools
Vc[m/min]
fn[mm/rev]
1stsetup
1stsetup
车刀
180
0,18
Externalturningtool
200
0,20
麻花钻Ø19
60
0,10
TwistdrillØ19
200
0,06
车刀
200
0,10
Externalturningtool
220
0,10
镗刀
150
0,08
Internalturningtool
180
0,10
攻丝刀
65
1,50
Threadingtool
100
1,50
内开槽刀具
60
0,06
Internalrecessing
130
0,08
tool
合计时间:
3’06min
Totaltime:
1’57min
Timesaved:
37%
准干式加工典型应用
盖板
Material:
GG20RD40
Machine:
HeckertBAZCWK400DSpeedrange:
5015,000rpm
冷却润滑剂:
原来(wet)乳化液
现在(MQL)准干式润滑剂
WetmachiningDrymachining
f
Cuttingspeed
Feedspeed
Cuttingspeed
Feedspeed
Tools
VC[m/min]
V[mm/min]Tools
VC[m/min]
Vf[mm/min]
Stepdrill
100
588
Solidcarbidestep
73
61
Ø12.5Ø15
drillØ5.8Ø10;Fire
Counterbore
50
90
Solidcarbidestep
73
441
Ø5.8Ø10
drillØ5.8;Fire
Solidcarbidedrill
100
327
Solidcarbidestep
73
505
Ø5.8
drillØ4.6;Fire
Solidcarbidedrill
100
270
Solidcarbidestepdrill
73
505
Ø4.5
Ø4.8.Ø12.5;Fire
Solidcarbidedrill
100
260
Solidcarbidestepdrill
73
517
Ø4.6
Ø4.5;Fire
Solidcarbidedrill
100
270
TapM14x1.5TiN
30
1023
Ø4.8
Solidcarbidedrill
100
328
Solidcarbidestep
73
441
Ø5.8
drillØ5.8;Fire
Solidcarbidedrill
100
549
Solidcarbidereamer
8,4
54
Ø12.5
Ø6G7TiAlN
TapM14x1.5;HSS
15
1024
CountersinkØ6.5
73
447
HSSdrillØ12.3
100
463
Ø6drilledouttoG7toleranceonspecialmachine
Totaltime:
5’24min
Totaltime:
1’48min
Timesaved:
67%
准干式加工典型应用
垫板
Material:
GG20RD40
Machine:
HeckertBAZCWK400DSpeedrange:
5015,000rpm
冷却润滑剂:
原来(wet)乳化液
现在(MQL)准干式润滑剂
WetmachiningDrymachining
f
Cuttingspeed
Feedspeed
Cuttingspeed
Feedspeed
Tools
VC[m/min]
V[mm/min]Tools
VC[m/min]
Vf[mm/min]
SCdrillØ3.2
80
145
SCstepdrill
73
598
Ø2.8,Fire
DrillØ2.5
35
28
SCreamer
18
210
Ø3H7TiAlN
TapM3TiAlN
30
142
SCstepdrill
70
562
Ø2.5,Fire
DrillØ2.7
35
30
SCcountersinkØ3,4
73
684
SCstepdrill
73
581
Ø3.2,Fire
EndmillØ3
110
47
Ø3drilledouttoH7toleranceonspecialmachine
TapM3TiN
SCstepdrill
Ø3.4,Fire
30
126
1592
1888
Totaltime:
3’12min
Totaltime:
1’30min
Timesaved:
53%
准干式加工典型应用
机架
Material:
16MnCr51.7131(DIN1017FL40x30)Machine:
HeckertBAZCWK400D
Speedrange:
5015,000rpm
冷却润滑剂:
原来(wet)乳化液
现在(MQL)准干式润滑剂
WetmachiningDrymachining
f
Cuttingspeed
Feedspeed
Cuttingspeed
Feedspeed
Tools
VC[m/min]
V[mm/min]Tools
VC[m/min]
Vf[mm/min]
NCspottingdrillØ10
70
80
NCspottingdrillØ10
80
250
SCtwistdrillØ4
63
100
SCtwistdrillØ4
90
760
SCtwistdrillØ9,8
77
450
SCtwistdrillØ9,8
77
860
Countersinkforcore
24
30
Countersinkforcore
47
250
M14x1,5
M14x1,5
Countersinkforcore
20
80
Countersinkforcore
46
280
M12x1,5
M12x1,5
Stepdrill
43
30
Stepdrill
72
180
Ø23/Ø12,5
ø23/ø12,5
SCtwistdrillØ9,0
80
450
SCtwistdrillØ9,0
80
665
Countersinkforcore
23
25
Countersinkforcore
70
300
M12x1,0
M12x1,0
CountersinkØ6/30°
8
40
Countersinkø6/30°
38
225
TapM12x1
11
300
Threadmiller
87
200
M12x1.5;pitch1
TapM14x1,5
19
300
Threadmiller
87
240
M14x1.5;pitch2
TapM12x1,5
17
300
Threadmiller
87
240
M12x1.5;pitch2
Productionon3machinetoolsProductiononamachiningcenter
madepossiblebytheuseofMQLtools
Totaltime:
15’42min
Totaltime:
6’36min
Timesaved:
58%
准干式加工典型应用
联接法兰盘
Material:
X10CrNiS1891.4305
(DIN668RD30)
Machine:
TRAUBTNA300
Speedrange:
505,000rqm
冷却润滑剂:
原来(wet)乳化液
现在(MQL)准干式润滑剂
WetmachiningDrymachining
Cuttingspeed
Feedfn[mm/rev]
Cuttingspeed
Feedfn[mm/rev]
Tools
VC[m/min]
Feedspeed
Vf[mm/min]
Tools
VC[m/min]
Feedspeed
Vf[mm/min]
Turningtool
220
0,20
TurningØ28
250
0,25
TwistdrillØ19
15
0,14
DisposabledrillØ19
160
0,06
Centeringdrill
19
0,12
DrillingØ8.7
60
0,08
TwistdrillØ8
10
0,12
DrillingØ10
60
0,08
FlatdrillØ18
34
0,10
Internalturning
250
0,10
FlatdrillØ10
13
0,12
Threadchasing
90
1,50
M22x1.5
Internalturningtool
152
0,12
Groovemilling
38
400
Internalturningtool
207
0,08
Thread
55
1,50
Recess
50
0,06
Groovemilling
19
70,00
Fewermachiningoperations
thankstomodifiedtools
Totaltime:
5’00min
Totaltime:
2’04min
Timesaved:
59%
准干式加工典型应用
盘件
Material:
AlCuMgPbF38(DIN1770Fl80x15)Machine:
TRAUBTNA300
Speedrange:
505,000rpm
冷却润滑剂:
原来(wet)乳化液
现在(MQL)准干式润滑剂
WetmachiningDrymachining
n
Cuttingspeed
Feed
Cuttingspeed
Feed
Tools
Vc[m/min]
f[mm/rev]Tools
Vc[m/min]
fn[mm/rev]
1stsetup
1stsetup
TMaxdrillØ25
64
0,12
TMaxdrillØ24
200
0,25
Externalroughturning
440
0,15
Externalroughturning
800
0,25
Externalfinishturning
485
0,08
Externalfinishturning
855
0,25
InternalturningØ26H7
90
0,08
InternalturningØ26H7
300
0,25
Chamfer1x45°
71
0,04
Chamfer1x45°
200
0,15
Totaltime:
2’45min
Totaltime:
0’45min
Timesaved:
73%
准干式加工典型应用
泵主轴
Material:
X35CrMo171.4122(DIN1013RD22)Machine:
new:
BrotherTC227
Speedrange:
010,000rpm
冷却润滑剂:
原来(wet)乳化液
现在(MQL)准干式润滑剂
Wetmachining
Drymachining
CuttingspeedFeedspeed
ToolsV[m/min]V[mm/min]
CuttingspeedFeedspeed
ToolsV[m/min]V[mm/min]
Solidcarbidemiller18,830
Solidcarbidemiller65207
Ø3,coated
Deburringmanual
MillerØ350742
Universalmillingmachine
Totaltime:
1’39min
Totaltime:
0’30min
cfcf
Timesaved:
70%
准干式加工典型应用
阀体
Material:
9SMnPb28K(DIN174Fl40x25)Machine:
TRAUBTNA300
Speedrange:
05,000rpm
冷却润滑剂:
原来(wet)乳化液
现在(MQL)准干式润滑剂
WetmachiningDrymachining
n
Cuttingspeed
Feed
Cuttingspeed
Feedfn[mm/rev]
Tools
VC[m/min]
f[mm/rev]Tools
VC[m/min]
Feedspeed
Vf[mm/min]
1stsetup
1stsetup
Predrilling
50
0,20
Facing
280
0,25
Predrilling
50
0,20
TMaxdrillØ19
170
0,20
Facing
470
0,08
Undercut
150
0,12
Roughturning
120
0,06
FitØ20H9turned
200
0,10
Insidediameter
ThreadM22x1,5
turning
120
0,06
milled
4000min1
500
Threadcutting
M22x1,5
10
1,50
Totaltime:
3’18min
Totaltime:
1’48min
Timesaved:
45%
准干式加工典型应用
法兰块
Material:
AlMgCuPb
F38
Machine:
DMGTwin65
Speedrange:
05,000rpm
冷却润滑剂:
原来(wet)乳化液
现在(MQL)准干式润滑剂
WetmachiningDrymachining
Cuttingspeed
Feedfn[mm/rev]
Cuttingspeed
Feedfn[mm/rev]
Tools
VC[m/min]
Feedspeed
Vf[mm/min]
Tools
VC[m/min]
Feedspeed
Vf[mm/min]
Roughing
250
0,30
Facing,roughing
275
0,20
Roughdrilling
50
0,12
Roughdrilling
125
0,20
Externalfinishing
230
0,10
Centering(2x)
225
300
Drilling(2x)
32
120
DrillingØ2,4(2x)
105
280
TappingM3(2x)
5
0,50
Centering(2x)/
180220
950
deburring
Internalfinishing
95
0,08
DrillingØ4.8(2x)
180
250
Recessing
47
0,05
Externalfinishing
275
0,15
TappingM3(2x)
4
0,50
2ndsetup
Internalfinishing95
0,15
Ø12E9
Roughcountersinking
60
0,10
Recessing
50
0,10
Boring
165
0,05
Facing,chamfering
345
0,15
Centering(7x)
70
125
Centering,deburring
160220
980
DrillingØ4.8(2x)
53
175
Milling
135
540
DrillingØ2H9(2x)
25
120
CounterboringØ8
250
250
DrillingØ2.5(5x)
32
120
DrillingØ2.4(5x)
90
240
TappingM3(5x)
3
0,50
TappingM3(5x)
4
0,50
Counterboring
50
80
DrillingØ2H9(2x)
100
300
Roughcountersinking
50
0,15
Ø24
Completedin2setupsofblanks.
Boring
Parting
200
120
0,12
0,12
Totaltime:
8’5min
Totaltime:
3,7min
Timesaved:
56,5%
准干式加工典型应用
导向杆
Material:
AlCuMgPbF38(DIN1798RD14)Machine:
TRAUBTNA300
Speedrange:
0-5,000rpm
冷却润滑剂:
原来(wet)乳化液
现在(MQL)准干式润滑剂
WetmachiningDrymachining
n
Cuttingspeed
Feed
Cuttingspeed
Feed
Centering
5
0,10
Centering
20
0,20
FinishingØ12f8
83
0,10
FinishingØ12f8
180
0,06
DeburringØ3
30
0,10
DeburringØ3
60
0,10
DrillØ6.8
12
0,10
DrillØ6.8
60
0,10
DrillØ9
15
0,10
DrillØ9
40
1,50
Tools
Vc[m/min]
f[mm/rev]Tools
Vc[m/min]
fn[mm/rev]
1stsetup
1stsetup
Threads
150
1,25
Threads
400
0,08
2ndsetup
2ndsetup
Centering
57
0,10
Centering
180
0,12
DrillingØ4.0
31
0,10
DrillingØ4.0
180
0,12
Turning
97
0,10
Turning
200
0,12
Threadchasing
67
8strokes
Threadchasing
90
8strokes
M14x1.5thread
M14x1.5thread
Deburring
97
0,12
Deburring
200
0,12
Totaltime:
4’21min
Totaltime:
2’08min
Timesaved:
49%