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Characteristics and application of plug milling method

plug milling, also known as z-axis milling method, is one of the most effective machining methods to achieve high removal rate metal cutting. For surface machining, grooving machining and machining with large tool overhang length of difficult to machine materials, the machining efficiency of insert milling method is much higher than that of conventional end milling method. In fact, when a large number of metal materials need to be cut quickly, the processing time can be shortened by more than half by using the plug milling method. In addition, insert milling processing also has the following advantages:

① it can reduce workpiece deformation; ② It can reduce the radial cutting force acting on the milling machine, which means that the worn spindle of the shafting can still be used for insert milling without affecting the machining quality of the workpiece; ③ The tool overhang length is large, which is very beneficial to the milling of the workpiece groove or surface; ④ It can realize the grooving processing of superalloy materials (such as Inconel). Insert milling method is very suitable for rough machining of mold cavity, and is recommended for efficient machining of aviation parts. One of the special purposes is to insert and mill turbine blades on three-axis or four-axis milling machines. This kind of processing usually needs to be carried out on special machine tools

when inserting and milling turbine blades, when one inspector samples and leaves a piece, it can be milled from the top of the workpiece down to the root of the workpiece. Through the simple translation of the X-Y plane, extremely complex surface geometries can be processed. When insert milling is implemented, the cutting edge of the milling cutter is formed by overlapping the profile of each blade. The depth of insert milling can reach 250mm without vibration or distortion. The cutting direction of the cutter relative to the workpiece can be downward or upward, but generally downward cutting is more common. When inserting and milling the inclined plane, the inserting and milling cutter makes a compound movement along the Z-axis and X-axis directions. In some processing occasions, the shear thickening characteristics of particle suspension system and its influencing factors can also be studied. Spherical milling cutters, face milling cutters or other milling cutters are used for milling grooves, milling profiles, milling slopes, milling cavities and other processing

special insert milling cutter is mainly used for rough machining or semi precision machining. It can cut into the concave part of the workpiece or cut along the edge of the workpiece, and it can also mill complex geometric shapes, including root digging. In order to keep the cutting temperature constant, all inserted milling cutters with shanks are internally cooled. The cutter body and blade of the slotting milling cutter are designed to cut into the workpiece at the best angle. Generally, the cutting edge angle of the slotting milling cutter is 87 or 90, and the feed rate range is 0.08 ~ 0.25mm/tooth. The number of blades clamped on each insert milling cutter depends on the diameter of the milling cutter. For example, a milling cutter with a diameter of 20mm can be installed with 2 blades, while a milling cutter with a diameter of f125mm can be installed with 8 blades. In order to determine whether the machining of a workpiece is suitable to adopt the insert milling method, the requirements of the machining task and the characteristics of the machining machine tool used should be mainly considered. If the machining task requires a high metal removal rate, the insertion milling method can greatly shorten the machining time

another suitable occasion for using the insert milling method is when the machining task requires a large axial length of the tool (such as milling large cavities or deep grooves). Because the insert milling method can effectively reduce the radial cutting force, it has higher machining stability than the side milling method. In addition, when the parts on the workpiece that need to be cut are difficult to reach by conventional milling methods, the plug-in milling method can also be considered. Because the plug-in milling cutter can cut up the metal, it can mill out complex geometric shapes. From the perspective of machine tool applicability, if the power of the processing machine tool used is limited, the plug milling method can be considered, because the power required for plug milling is less than that of spiral milling, so it is possible to use old-fashioned machine tools or machine tools with insufficient power to obtain higher processing efficiency. For example, insert milling deep grooves can be realized on a 40 grade machine tool, and this kind of machine tool is not suitable for machining with long edge spiral milling cutter, because the radial cutting force generated by spiral milling is large, which is easy to make the spiral milling cutter vibrate. Due to the low radial cutting force during insert milling, it is very suitable for old machine tools with worn spindle bearings. Insert milling method is mainly used for rough machining or semi precision machining. A small amount of axial deviation caused by the wear of machine tool shafting will not have a great impact on the machining quality. As a new NC machining method, insert milling method puts forward new requirements for CNC machining software

at present, there is still a lot of work to be done in the development of applicable software. Software suppliers are beginning to adapt or sort about 95% of plastic films from mixed waste, and re compile processing software that can handle a large number of z-axis codes. This software must be highly flexible to adapt to various processing tasks. Whether for large metal cutting (which is common in mold processing) or the processing of aviation parts with complex geometry, insert milling method will be the preferred processing method. Compared with the conventional processing method, the plug milling method has high processing efficiency and short processing time, and can be applied to various processing environments. It is not only suitable for the processing of single small batch disposable prototype parts, lansbergen said, but also suitable for the manufacturing of large batch parts. Therefore, it is a processing technology with great development prospects

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