Cutting Tools Classification and Selection
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The vast majority of cutting tools are machine-based, but they are hand-friendly. Since the tools used in machining are basically used for cutting metal materials, the term "tool" is generally understood as a metal cutting tool. Cutting tools for wood are called woodworking tools.
The development of cutting tools plays an important role in the history of human progress. As early as the 28th to the 20th century BC, brass cones and copper cones, drills, and knives were used in China. In the late Warring States period (3rd century BC), copper knives were made due to the mastery of carburizing technology. The drills and saws at the time were similar to modern flat drills and saws.
However, the rapid development of cutting tools came in the late 18th century with the development of machines such as steam engines. In 1783, René of France first produced a milling cutter. In 1792, Modsley of the United Kingdom made taps and dies. The earliest documented invention of the twist drill was in 1822, but it was not produced as a commodity until 1864.
The tool at that time was made of high-carbon tool steel and the allowable cutting speed was about 5 m/min. In 1868, Muchert made a tool alloy steel containing tungsten. In 1898, Taylor and the United States. White invented high speed steel. In 1923 Schreiter of Germany invented cemented carbide.
When alloy tool steels are used, the cutting speed of the tool is increased to about 8 m/min. When high-speed steel is used, it is more than doubled. When using carbide, it is more than twice that of high-speed steel. The workpiece surface quality and dimensional accuracy are also greatly improved.
Due to the high price of high-speed steel and hard alloys, the tool has a welded and mechanically clamped structure. From 1949 to 1950, the United States began to use indexable inserts on lathe tools, and soon it was applied to milling cutters and other tools. In 1938, Germany's Degussa obtained patents on ceramic tools. In 1972, General Electric of the United States produced polycrystalline synthetic diamond and polycrystalline cubic boron nitride inserts. These non-metallic tool materials allow the tool to cut at higher speeds.
In 1969, the Sandvik Steel Company of Sweden patented a chemical vapor deposition process for the production of titanium carbide coated carbide inserts. In 1972, Bangsa and Rakoland of the United States developed a physical vapor deposition method to coat carbide or HSS cutters with a hard layer of titanium carbide or titanium nitride. The surface coating method combines the high strength and toughness of the base material with the high hardness and wear resistance of the surface layer, so that the composite material has better cutting performance.
The tool can be divided into five categories according to the form of the workpiece surface. Tool for machining a variety of outer surfaces, including turning tools, planers, milling cutters, broaches, boring tools, etc.; hole-cutting tools, including drills, reamers, boring tools, reamers, and broaches on the inside; thread machining Tools, including taps, dies, automatic opening and closing threads, thread turning tools and thread milling cutters; gear cutting tools, including hobs, pinion cutters, shaving cutters, bevel gear cutting tools, etc.; cutting tools, including inserts Circular saw blades, band saws, hack saws, cutting tools, saw cutters, etc. In addition, there are combination cutters.
According to the cutting movement mode and the corresponding blade shape, the tool can be divided into three categories. General-purpose tools, such as turning tools, planers, milling cutters (not including shaped turning tools, shaping planers, and forming cutters), boring tools, drills, reamers, reamers, saws, etc.; forming tools; cutting edges of such tools It has the same or nearly the same shape as the cross-section of the workpiece to be machined, such as forming lathes, forming planers, forming cutters, broaches, conical reamers, and various thread cutting tools, etc.; Teeth or similar workpieces, such as hobs, pinions, shavers, bevel gears, bevel gear cutters, etc.
The structure of various tools consists of the clamping part and the working part. The clamping part and the working part of the monolithic tool are made on the tool body; the working part (blade or blade) of the insert tool is mounted on the tool body.
The clamping part of the tool has holes and handles. The holed cutter relies on the inner hole to be set on the spindle or mandrel of the machine tool, and the torsional moment is transmitted by means of an axial key or an end face key, such as a cylindrical milling cutter, a set face milling cutter and the like.
The shanked tool usually has three kinds of rectangular shank, cylindrical shank and tapered shank. The lathes, planers, etc. are generally rectangular shanks; the conical shank is subjected to axial thrust by a taper, and the torque is transmitted by means of friction; the cylindrical shank is generally applicable to tools such as smaller twist drills, end mills and the like, and is cut by a clamp The resulting friction forces transmit torsional moments. The shank of many shanked tools is made of low-alloy steel, while the working part is made of high-speed steel butt-welded.
The working part of the tool is the part that generates and handles the chip, including the cutting edge, the structure that breaks or rolls the chip, the space for chip removal or storage, and the channel of the cutting fluid. The working parts of some tools are cutting parts, such as turning tools, planing tools, boring tools, and milling cutters; the working parts of some tools include cutting parts and calibration parts, such as drills, reamers, reamers, and internal surface pulls. Knives and taps. The role of the cutting part is to remove the chip with the cutting edge, and the role of the calibration part is to trim the machined surface and guide the tool. The structure of the working part of the tool has three types: integral type, welding type, and mechanical clamping type. The overall structure is to make the cutting edge on the blade body; the welding structure is to braze the blade to the steel blade body; there are two kinds of mechanical clamping structure, one is to clamp the blade on the blade body, and the other is The brazed cutter head is clamped on the cutter body. Carbide tools are generally made of welded structures or mechanical clamping structures; porcelain tools are used mechanical clamping structure.
The geometric parameters of the cutting part of the tool have a great influence on the level of cutting efficiency and the quality of the processing. Increasing the rake angle can reduce the plastic deformation when the rake face presses the cutting layer, reduces the frictional resistance of the chip flowing through the front, and reduces the cutting force and cutting heat. However, increasing the rake angle will also reduce the strength of the cutting edge and reduce the heat dissipation volume of the cutter head.
When selecting the angle of the tool, it is necessary to consider the influence of various factors, such as workpiece material, tool material, and processing properties (roughness, fine processing), etc., and must be reasonably selected according to specific conditions. Generally speaking, the tool angle refers to the manufacturing and measurement of the labeling angle. In the actual work, due to the different installation positions of the tool and the direction of the cutting movement, the actual working angle and the marked angle are different, but the difference is usually very small. .
The materials used to make the tool must have high hardness and wear resistance at high temperatures, necessary bending strength, impact toughness and chemical inertness, good processability (cutting, forging, heat treatment, etc.), and are not easily deformed.
Usually when the material hardness is high, the abrasion resistance is also high; when the bending strength is high, the impact toughness is also high. However, the higher the material hardness, the lower its flexural strength and impact toughness. High-speed steel has high bending strength and impact toughness, and good machinability. Modern is still the most widely used tool material, followed by hard alloys.
Polycrystalline cubic boron nitride is suitable for cutting high hardness hardened steel and hard cast iron; Polycrystalline diamond is suitable for cutting non-ferrous metals, alloys, plastics and FRP; Carbon tool steel and alloy tool steel are only used now For boring tools, dies and taps and other tools.
Cemented carbide indexable inserts have now been coated with titanium carbide, titanium nitride, hard aluminum oxide layers or composite hard layers by chemical vapor deposition. The physical vapor deposition method being developed can be used not only for carbide tools but also for high-speed steel tools such as drills, hobs, taps, and milling cutters. The hard coating acts as a barrier against chemical diffusion and heat conduction, slows down the wear of the tool during cutting, and increases the life of the coated insert by approximately 1-3 times compared to the uncoated one.
Due to the high temperature, high pressure, high speed, and parts working in corrosive fluid media, more and more difficult-to-machine materials are used, and the automation level of cutting and the requirements for processing accuracy are getting higher and higher. In order to adapt to this situation, the development direction of the tool will be to develop and apply new tool materials; to further develop the tool's vapor deposition coating technology, to deposit a higher hardness coating on a high-toughness, high-strength substrate to better solve The contradiction between the hardness and strength of the tool material; the development of the structure of the indexable tool; the improvement of the tool's manufacturing precision, the reduction of the difference in product quality, and the optimization of the use of the tool.
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