The Whirling machine plays a vital role in Die Pin processing. It is specially designed for single-head screw pump and stator Die Pin milling processing. It has the characteristics of high stability and high precision, which can greatly improve processing efficiency and reduce costs at the same time. In the domestic screw pump industry, Whirling machines are widely used equipment.
In terms of application scenarios, Whirling machines are widely used in automobile manufacturing, aerospace, electronics manufacturing and other industries. It can process Die Pin of various complex shapes to meet the needs of different industries for high-precision parts. At the same time, the high-precision processing capabilities of the Whirling machine can ensure the dimensional accuracy and surface quality of the Die Pin, and improve the reliability and performance of the product.
Advantages of Whirling in Die Pin processing
The advantages of Whirling in Die Pin processing are mainly reflected in the following aspects:
High processing efficiency
- High cutting speed: The tool of Whirling rotates extremely fast and can reach high linear speed, which greatly increases the amount of material removed per unit time. For example, when processing some metal Die Pin with moderate hardness, the processing efficiency can be improved several times or even higher than traditional milling methods. For mass production of mold cores, the processing cycle can be significantly shortened and production efficiency improved.
- Continuous processing: Whirling can achieve continuous cutting processing, reducing pauses and tool changes during processing. In Die Pin processing, especially for Die Pin with complex shapes, this continuous processing feature can avoid the accumulation of errors caused by frequent tool changes and repositioning, ensuring the efficiency and consistency of processing.
High processing accuracy
- High motion accuracy: The structural design and control system of the Whirling machine can ensure the relative motion accuracy between the tool and the workpiece. In Die Pin processing, Whirling can accurately process some dimensions, shapes and positional accuracy that require high precision. For example, it can process high-precision Die Pin cavities, core contours and dimensions to ensure that the mold Mold closing accuracy and molding accuracy.
- Good surface quality: Due to the high-speed cutting and precise feed control of Whirling, the surface roughness of the processed Die Pin is low and the surface quality is good. This can not only reduce subsequent surface treatment processes such as polishing and grinding, reduce processing costs, but also help improve the mold release performance and product surface quality.
Wide range of application
- Strong material adaptability: Whirling can process Die Pin of a variety of materials, including steel, iron, alloys, ceramics, etc. Whether it is a metal material with higher hardness or a brittle ceramic material, Whirling can select appropriate tools and processing parameters according to the characteristics of the material to achieve efficient and precise processing.
- Complex shape processing capabilities: The shape of the Die Pin is often complex, with various curved surfaces, cavities, cores and other structures. Tornado milling can flexibly process Die Pin of various complex shapes through multi-axis linkage and tool rotation to meet the design needs of different molds.
Cost savings
- Long tool life: The carbide tools used in Whirling have high hardness and wear resistance, and can maintain good cutting performance during high-speed cutting, and the tool has a long service life. This reduces the frequency of tool replacement and reduces tool usage costs.
- Low energy consumption: Compared with some large-scale processing equipment, the power of Whirling is relatively small and the energy consumption is low. In the long-term Die Pin processing process, a lot of energy costs can be saved.
Easy and flexible operation
- Simple installation and debugging: The structure of the cyclone mill is relatively simple, and it is more convenient to install and debug it with ordinary machine tools. In the Die Pin processing workshop, operators can quickly install the Whirling machine on the machine tool and perform debugging and processing, which improves the efficiency of the equipment.
- Adjustable processing parameters: The control system of Whirling can easily adjust processing parameters, such as cutting speed, feed amount, milling depth, etc. Operators can flexibly select and adjust processing parameters according to the material, shape and processing requirements of the Die Pin to achieve the best processing effect.
The process of Whirling Die Pin
The process of Whirling Die Pin generally includes the following steps:
1.Preparation
Choose a suitable whirling machine and make sure it is securely mounted. Select appropriate tools and fixtures based on the material and size of the Die Pin.
2.Install the Die Pin
Install theDie Pin on the workbench of the Whirling machine and fix it with a clamp. Make sure the Die Pin is in the correct position and orientation.
3.Adjust the tool
According to the processing requirements of the Die Pin, adjust the angle, depth, feed speed and other parameters of the Whirling tool. Make sure the tool has good contact with the Die Pin and the cutting process is stable.
4.Start processing
Start the whirlwind milling machine and make the tool rotate at high speed. At the same time, through the movement of the workbench, the Die Pin and the tool move relative to each other to achieve cutting processing. During the processing, pay attention to the cutting situation and adjust the feed speed and cutting depth in time to ensure the processing quality.
5.Cleaning and inspection
After processing is completed, turn off the whirlwind milling machine and clean the chips and debris on the workbench. The Die Pin is then inspected to ensure that its dimensions and surface quality meet requirements. Further trimming and polishing can be done if necessary.
6.Maintenance and maintenance
Regularly maintain and maintain the Whirling machine, including cleaning, lubrication and checking the working status of each component. Replace worn tools and fixtures in a timely manner to ensure the normal operation and processing accuracy of the machine tool.
It should be noted that when performing whirlwind milling of the Die Pin, the operating procedures should be strictly followed to ensure the safety of the operators. At the same time, according to the specific conditions of the Die Pin, appropriate processing parameters and process methods are selected to obtain the best processing effect.
What are the common problems with Whirling of Die Pin?
1.Surface Quality Issues
Surface roughness does not meet requirements
- Reason: Tool wear is a common factor. When the cutting edge of the tool becomes blunt, the cutting force will increase, causing the cutting process to be unstable, causing vibration marks on the surface of the Die Pin and increasing surface roughness. In addition, unreasonable cutting parameter settings, such as too fast a feed speed or too large a cutting depth, will also degrade the surface quality. For example, when processing high-precision plastic Die Pin, if the feed speed exceeds the reasonable range that the tool and material can bear, obvious knife marks will be left on the surface of the mold core.
- Solution: Check the wear of the cutting tools regularly and replace seriously worn cutting tools in a timely manner. At the same time, according to the material of theDie Pin and the performance of the tool, the cutting parameters are reasonably adjusted, such as appropriately reducing the feed speed and cutting depth, to obtain better surface quality.
Burns appear on the surface
- Reason: Mainly because the heat generated during the cutting process is too high and the heat is not dissipated in time. During tornado milling, the high-speed friction between the tool and the mold core will generate a large amount of heat. If there is not enough coolant or the coolant injection position is inappropriate, the heat will accumulate in the cutting area, causing the metal surface of the mold core to deteriorate. The phase structure changes and burn marks appear.
- Solution: Ensure adequate coolant supply, and adjust the coolant injection angle and position so that it can effectively cool the cutting area. At the same time, cutting parameters can be optimized to reduce the generation of cutting heat, such as reducing the cutting speed or using intermittent cutting.
2.Dimensional accuracy issues
Size out of tolerance
- Reasons: First, the accuracy of the machine tool itself. If there are deviations in the coordinate axis accuracy and positioning accuracy of the Whirling machine, it will directly affect the processing dimensions of the Die Pin. For example, the wear of the machine tool’s screw or the decrease in guide rail accuracy will lead to errors in the tool’s motion trajectory. The second is programming errors. In CNC tornado milling, if the programmer incorrectly calculates the size of the mold core or sets wrong coordinate values in the program, a mold core with a size that does not meet the requirements will be processed.
- Solution: Regularly conduct accuracy testing and calibration of the Whirling machine, including checking and adjusting the positioning accuracy and repeat positioning accuracy of the coordinate axes. For programming errors, it is necessary to strengthen the review and verification of the programming process, conduct simulated processing or trial cutting before processing, and promptly discover and correct errors in the program.
Poor shape accuracy
- Reason: The unreasonable cutting path of the tool is an important reason. For example, when processing a Die Pin with a complex curved surface, if the tool path is improperly planned and cannot accurately cut along the curved surface contour, the shape accuracy of the mold core will be reduced. In addition, the vibration of the tool will also affect the shape accuracy. When the rigidity of the tool system is insufficient or the cutting force is too large, the tool will vibrate, causing the surface shape of the cut mold core to deviate from the design requirements.
- Solution: Use professional CAM software to optimize the tool path planning to ensure that the tool can accurately cut along the contour of the mold core. At the same time, improve the rigidity of the tool system, such as using appropriate tool handles and tool structures, reducing the overhang length of the tool, and reasonably controlling cutting forces to avoid tool vibration
3.Tool Damage Problem
Tool chipping
- Reason: Improper selection of cutting parameters is one of the main reasons. If the cutting force is too large and exceeds the bearing capacity of the tool edge, it will cause the tool to chip. For example, when processing a mold steel core with high hardness, using too high a feed rate and cutting depth can easily cause the cutting edge of the tool to break. In addition, tool quality problems may also cause chipping, such as insufficient hardness of the tool material or defects in the tool manufacturing process.
- Solution: According to the material hardness of the Die Pin and the performance of the tool, reasonably select the cutting parameters to avoid excessive cutting force. When selecting tools, choose tools with reliable quality and perform quality inspections on the tools, such as checking whether the integrity and hardness of the cutting edge meet the requirements
Too much tool wear
- Reasons: First, the cutting performance of the material is poor. If the core material contains hard points or components with high wear resistance, it will accelerate the wear of the tool. For example, when processing mold materials containing cemented carbide particles, these particles will cause severe friction on the tool surface, leading to accelerated tool wear. Second, the cutting environment is harsh. If the chips generated during the cutting process cannot be discharged in time, secondary cutting will occur on the tool, thereby accelerating tool wear.
- Solution: Choose appropriate tool materials and coatings based on the cutting performance of the material. For example, for high-hardness materials, choose tools with high-hardness coatings. Improve the cutting environment and optimize the chip removal system to ensure that chips can be discharged smoothly and reduce the impact of chips on the tool.
What are the application fields of Whirling machine for Die Pin processing?
Whirling machines have a wide range of applications in processing Die Pin. Here are some of the main ones:
1.Plastic mold processing field
- Injection Die Pin processing: Whirling machine plays an important role in manufacturing the core of injection mold. For example, when producing cores for injection molds such as home appliance casings and automotive plastic interior parts, cyclone milling machines can accurately process complex cavity and core structures. Since injection molds have high requirements on the dimensional accuracy and surface quality of the mold core, the cyclone milling machine can achieve high-precision milling, and the surface roughness of the processed mold core can reach μm level, ensuring the molding quality and appearance accuracy of plastic products.
- Blow Die Pin processing: used to manufacture various plastic bottles, plastic containers and other blow mold core processing. For example, for the common beverage bottle blow mold core, the Whirling machine can use its high-speed rotating cutter and precise feeding system to process the internal structure of the mold core that meets the requirements of the blow molding process to ensure the wall thickness of the plastic bottle during the blow molding process. Uniform and regular in shape.
2.Die casting mold processing field
- Aluminum alloy die-casting mold core processing: In the aluminum alloy die-casting industry, such as automobile engine parts, aluminum alloy wheels and other die-casting Die Pin processing. Tornado milling machines can handle aluminum alloys, a relatively soft material that requires stringent dimensional accuracy and surface quality. It can process mold cores with complex cooling channels and high-precision cavities, which helps uniform filling and rapid cooling of molten metal during the die-casting process, thereby improving the quality and production efficiency of die-cast products.
- Zinc alloy die-casting Die Pin processing: For zinc alloy die-casting mold cores, Whirling machines are also suitable. For example, in the core processing of die-casting molds for electronic equipment casings, Whirling machines can accurately process fine textures and structures, meet the high requirements of zinc alloy die-casting molds for the core, and produce die-cast products with excellent surface quality.
3.Precision mechanical parts processing field (as an extension related to molds)
- Aerospace parts processing: In the aerospace field,Whirling machines are also used to process mold cores for some small parts with complex shapes. For example, the mold core of a small blade mold for an aerospace engine. Due to the extremely high requirements for precision and quality of aviation parts, the cyclone milling machine can use its high precision and high stability characteristics to process the mold core that meets strict standards, and then produce Blades with extremely high precision ensure the performance and safety of aeroengines.
- Precision instrument parts processing: When manufacturing mold cores for precision instruments, such as high-precision calipers, micrometers and other Die Pin, the Whirling machine can process micron-level precision dimensions and complex shapes to meet the needs of precision instruments. Stringent requirements for part accuracy and surface quality.
