When the mold is processed by the traditional EDM method, the physical-mechanical properties of the surface of the workpiece will be damaged during the local high-temperature discharge ablation process on the surface of the workpiece. Frequent cracks will often occur on the surface of the cavity, and it is difficult to ensure the quality of the workpiece. . And EDM is very slow, low efficiency, but high cost. Therefore, many mold manufacturers are reluctant to use EDM, but directly use hard materials to mill and process molds. At this time, tool breakage has become an important issue for everyone. Unusual damage to the tool due to exceeding the load conditions allowed by the tool not only wastes money, but also destroys the entire process. Therefore, by maximizing the load at the optimum level of the tool, the maximum benefit can be obtained from the process.
However, one of the challenges in this area is the constant change in the material removal rate of the tool path during milling. In a typical high-speed roughing path with a depth of cut and a cutting width of 10% of the tool diameter, the material removal rate will reach 10 times the assumed value when the tool begins to enter the channel. This level is reached when the tool enters the inner corner. 5 times. The peak in these loads is the main cause of tool failure. The general treatment of each factory is to change the feed rate, depth of cut or cut width. Although reducing any of these cutting parameter values ​​may cause the peak load condition to return to a level below the threshold, this step will also reduce the overall tool path metal removal rate, thereby reducing productivity. Therefore, a better way to solve this problem should be to control the constant material removal rate.
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