Endmills-Wotek Precision Tools Co., LTD.

02/08/2024

29/07/2022

模具是什麼？常見加工問題總整理

模具是製造業中常見的零件之一，它與產品的質量、精細程度與生產的成本有很大的關係，想要開發一項新產品之前，一定要先了解模具是什麼、有哪些應用範圍？而且要對它的製造流程有初步的認識，才能隨時在開發及生產過程視情況調整使用，今天我們把使用模具前需要有的基礎知識和常見問題分享給您，幫助大家更認識這個重要的零件！

網站文章連結
https://www.endmills-wotek.com/blog/detail/37

Mold Making refers to the processing of forming and billet making tools, in addition to shear and die cutting dies. Typically, the mold has two parts, an upper mold and a lower mold. By placing the steel plate between the upper and lower dies, the forming of the material is achieved under the action of the press, and when the press is opened, the workpiece determined by the shape of the die is obtained or the corresponding waste material is removed. Workpieces as small as electronic connectors and as large as the dashboard of a car can be molded.

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02/07/2020

2020 CME中國機床展
展出時間：2020年7月1日至 7月4 日止
舉辦地址：上海虹橋國家會展中心
攤位號碼: 1-B16
展覽時間: 9:00 AM-17:00 PM

2020 CME CHINA MACHINE TOOL EXHIBITION
Exhibition: 2020 CME
Venue: National Exhibition and Convention Center-(Shanghai)
Date: From July 1 to July 1, 2020.
Time: 9:00 AM-17:00 PM
Booth no: 1-B16

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目前上海展出中，歡迎至現場指教，攤位號1-B16

02/07/2020

12/06/2020

週五好文分享

(高速銑削SKD61 模具鋼用鎢鋼端銑刀製程參數最佳化設計)

由於航太產業、模具加工業、汽機車零件產業與 3C產品等加工領域發達，使得銑削工件的端銑刀需求量大增，且科技的進步，使產品的精密度要求越來越高，故高精度銑刀需求相當迫切需要。切削刀具是製造工業上非常重要的技術工具，銑刀品質的好壞，直接影響切削性能、刃口磨損、銑刀壽命…等。銑刀之刀刃研磨是銑刀製造最重要過程，也是決定銑刀幾何形狀精度及切削性能之關鍵。銑刀刀刃幾何形狀複雜，具不同的工件材料，其適用的銑刀幾何角度基本上也不相同。SKD61 模具鋼具有高韌性、高強度、耐磨耗、易切削及容易表面處理等特性，為業界在製做模具上有相當的應用，模具鋼因而稱之。目前SKD61 模具鋼之加工方式為先採粗切削加工至預留尺寸，再經手工研磨、拋光等加工製程，然後再經試模、合模，直到合乎要求為止，相當費時且耗費成本。由於高速銑削精度極高，故若使用高速銑削，可因此縮短手工研磨及拋光之工時，顯著縮短製模週期，大大縮減了製造成本與時程，故模具的製作若得以應用高速銑削的方式進行有效率的加工，將對產業界的競爭力有著其莫大的助益。因此，研磨適當的銑刀幾何角度及選用最佳的切削條件來高速銑削SKD61 模具鋼，以增進銑刀壽命，降低生產成本，是模具製造業者所企盼的。
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(High Speed Milling SKD61 Solid Carbide End Mills for Die Steel Process Parameter Optimized Design)

The demand for end mills milling workpieces has increased significantly due to the development of the aerospace industry, mold processing industry, automotive parts industry and 3C products, and the advancement of technology has made the precision of products boosts demanding. Cutting tools are very important technical end mills in the manufacturing industry, the quality of the end mill directly affects the cutting performance, edge wear, end mill life...etc. The sharpening of the flute edge of a end mill is the most important process in the manufacture of a end mill and is the key to determining the geometric accuracy and cutting performance of the end mill. SKD61 die steel has high toughness, high strength, abrasion resistance, easy cutting and surface treatment, etc. It has been used in the industry for making molds. The current processing method of SKD61 die steel is first rough cutting to the pre-cutting area, then grinding by hand, polishing and other processing processes, and then the test mold, and then the mold until it meets the requirements, very time-consuming and costly. Due to the high precision of high speed milling, the use of high speed milling can shorten the manual grinding and polishing time, significantly shorten the mold making cycle and greatly reduce the production cost and time, therefore, if the mold making can be efficiently processed by high speed milling, it will greatly help the competitiveness of the industry. Therefore, grinding the appropriate end mill geometry and choose the best cutting conditions to high speed milling SKD61 die steel, in order to improve the end mill life, reduce production costs, is the expectations of mold makers.
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05/06/2020

週五好文分享

(提高無鉛黃銅合金的加工性能)

本文涉及無鉛黃銅合金的加工性的基礎研究。分析了微結構和矽作為合金元素對切屑形成、切削力、刀具溫度和刀具磨損的影響。在此基礎上，研究了提高加工性的各種方法，以實現高性能切削加工。本文重點研究了TiB2、DLC和金剛石等各種刀具塗層對磨料和黏性刀具磨損的影響。除了刀具磨損的顯著降低外，通過對刀具塗層的調整，實現了無鉛黃銅合金的乾式車削。此外，還對PCD刀具的性能和高壓冷卻液供應策略進行了研究。

黃銅合金具有高導熱性、高導電性和出色的抗菌性能，因此被廣泛應用於電子電氣、汽車、衛生行業等各個行業。由於在製造黃銅零件時需要大量的切削加工，因此通常會在黃銅中加入不同的合金元素來提高加工性。在這種情況下，最重要的元素是鉛，它可以提高切削性，使其具有優良的斷屑率、低刀具磨損和高適用切削參數。這些方面可以用兩個基本現象來解釋。首先，鉛在黃銅中的溶解度很低，因此，鉛在整個微觀結構中，特別是在晶界處會發生偏析。因此，剪切強度明顯降低，導致斷屑現象非常好。其次，鉛的熔化溫度Tm=327.5℃，鉛的熔化溫度很低。在切削過程中，薄的半流體鉛膜可以減少摩擦力，從而減少切削力和刀具磨損。
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(Machinability Enhancement of Lead-Free Brass Alloys)

This paper deals with fundamental investigations on the machinability of lead-free brass alloys. The effect of microstructure and silicon as alloying element on chip formation, cutting forces, tool temperatures and tool wear is analyzed during external turning. Based on that, various approaches for machinability enhancement were investigated in order to enable high performance cutting operations. The paper focuses on the influence of various tool coatings such as TiB2, DLC and diamond on abrasive and adhesive tool wear. Besides a significant decrease of tool wear, dry turning of lead-free brass alloys was realized by adapted tool coating. Moreover, investigations on the performance of PCD tools as well as high-pressure coolant supply strategy were carried out.

Brass alloys are characterized by high thermal and electric conductivity as well as outstanding antibacterial properties and are therefore widely used in various industries such as electric and electronics, automotive and sanitary industry. Due to a high amount of cutting operations when manufacturing brass components, different alloying elements enhancing the machinability are usually added to brass. The most important element in this context is lead, improving the machinability with regard to excellent chip breakage, low tool wear and high applicable cutting parameters. These aspects can be explained by two basic phenomena. First of all, solubility of lead in brass is very low and consequently, lead segregates in the entire microstructure, particularly at the grain boundaries. Hence, shear strength is significantly reduced, resulting in very good chip breakage. Secondly, lead exhibits a low melting temperature of Tm = 327.5 °C. During cutting, a thin, semifluid lead film reduces friction and thereby, cutting forces and tool wear.
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30/05/2020

周末好文分享

(Ti-6Al-4V(鈦-6鋁-4釩)的可持續銑削；研究銑削方向、銑刀螺旋角和低溫冷卻劑類型的影響)

Ti-6Al-4V作為最常用的鈦合金，具有優異的機械性能和耐腐蝕性能，為其在世界範圍內工業需求量持續上升的首要原因。鈦合金的非比尋常的力學性能被視為其成型工藝的阻礙，銑削工藝也不例外。切削區周圍產生強烈的熱熔劑是造成合金加工性差和加工持續性低的一個既定原因。本文的介紹試圖通過研究銑削方向、銑刀的螺旋角、切削速度以及低溫冷卻液和潤滑劑的種類對銑刀損傷、切削能耗、加工成本、銑削力和工作面粗糙度等可持續性措施的影響，來提高銑削Ti-6Al-4V的可持續性。研究發現，與常用的兩種低溫冷卻劑（積雪二氧化碳和液氮）相比，微潤滑在降低銑刀磨損、工件表面粗糙度、工藝成本和能耗方面的效果更好。此外，在銑刀磨損、工件表面質量和加工成本方面，下銑加工的效果大大優於上銑加工。同樣，高水平的銑刀螺旋角和切削速度也證明對銑削的可持續性有幫助。
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(Sustainable Milling of Ti-6Al-4V: Investigating the Effects of Milling Orientation, End mill's Helix Angle, and Type of Cryogenic Coolant)

Ti-6Al-4V, the most commonly used alloy of titanium, possesses excellent mechanical properties and corrosion resistance, which is the prime reason for the continual rise in its industrial demand worldwide. The extraordinary mechanical properties of the alloy are viewed as a hindrance when it comes to its shaping processes, and the process of milling is no exception to it. The generation of intense heat flux around the cutting zones is an established reason of poor machinability of the alloy and unacceptably low sustainability of its machining. The work presented in this paper attempts to enhance sustainability of milling Ti-6Al-4V by investigating the effects of milling orientation, end mill's helix angle, cutting speed, and the type of cryogenic coolant and lubricant on the sustainability measures, such as end mill damage, cutting energy consumption, process cost, milling forces, and work surface roughness. It was found that micro-lubrication is more effective than the two commonly used cryogenic coolants (carbon dioxide snow and liquid nitrogen) in reducing end mill wear, work surface roughness, process cost, and energy consumption. Furthermore, down-milling enormously outperformed up-milling with respect to end mill wear, work surface quality, and process cost. Likewise, the high levels of end mill's helix angle and cutting speed also proved to be beneficial for milling sustainability.
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22/05/2020

週五好文分享

(硬質合金立銑刀在AISI 1045鋼上的量能使用情況分析)

加工製造工藝對工業發展和經濟增長有很大的影響。為了優化這些工藝，人們對許多重要因素進行了研究。在過去的幾年裡，能量和功率被作為參數來驗證這些過程的效率。對能源消耗狀態的監測可以作為生產過程行為的一個指標。主要的挑戰是將能源使用量轉化為實際的指標，因為在加工過程中，由於機床的動態特性和加工過程中相互影響的相關因素的多樣性，對能源的監測帶來了挑戰。刀具磨損和刀具壽命扮演著重要角色，對成本和效率都有重大影響，尤其是在計算機輔助加工中。雖然經過多年的不斷研究，但直到現在，對刀具磨損狀態的監測仍然是一項複雜的工作。因此，在本研究中，採用，勢能法分析了一種特定類型的硬質合金立銑刀的使用情況。對具有特定物理和化學特徵的刀具進行能量極限估計，因為它可以簡化刀具壽命估計和換刀時機預測。用硬質合金立銑刀在AISI 1045鋼上進行一系列實驗，定期測量刀具的磨損和所需能量，直到刀具壽命結束，以分析切削刀具在達到使用壽命結束前是否能向工件材料傳遞一定的能量。

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(Energy Usage Analysis of Carbide End Mills on AISI 1045 Steel)

Machining and manufacturing processes have a strong influence on industry development and economic growth. Many important factors have been studied in order to optimize these processes. Over the last few years’ energy and power have been used as parameters to verify the efficiency of these processes. Monitoring the state of energy consumption may serve as an indicator of the manufacturing process behavior. The main challenge is to translate the energy usage into a practical indicator, since monitoring energy presents a challenge due to the dynamic characteristics of the machines and the diversity of associated factors interacting with each other during the machining processes. Tool wear and tool life expectancy are other important issue that have a significant impact on both, cost and efficiency, especially, in computer assisted processes. Although it has been continuously studied over many years, until now, monitoring the state of tool wear has remained a complex task. Thus, in this study, a specific type of carbide end mill is analyzed using, a potential energy approach. The energy limit for a cutting tool with specific physical and chemical features will be estimated since it can simplify the tool life estimation and the tool change timing prediction. A series of experiments are performed with carbide end mills on AISI 1045 steel, periodically measuring the tool wear and the required energy until the end of tool life, to analyze if a cutting tool could transmit a specific amount of energy to the work piece material before reaching the end of its useful life.

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15/05/2020

週五好文分享

(微型銑削中的銑刀磨損測量協議)

微型銑削可以快速地生產出小而精密的零件，用於機電、航空航天和醫療領域。由於其尺寸小，微型銑刀的磨損速度快且不可預知，因此銑刀磨損難以測量，而且對銑刀磨損的理解不足，會導致銑刀更換次數過多，生產效率降低。因此，本文提出了一種新的微型銑刀磨損測量協議，以克服這些問題。在ISO標準中找到的一套嚴格的標準對於微銑的研究是不切實際的。這裡的方法允許在不同材料和情況下進行比較，並詳細說明了實現這一目標必須滿足的某些標準。為了評估該協議的微型工具被用來加工三種材料：黃銅，鈦和哈氏合金;銑削磨損產生的磨損曲線。使用所描述的協議，這些磨損曲線可以與大型銑刀的磨損曲線進行類似的分析。對所加工的槽的輪廓分析提供了關於銑刀磨損的寶貴信息，而直接測量是不可能的。這種新的協議提供了一種分析和報告微型端銑刀磨損的新方法，可以在不同的加工條件下和/或銑削不同的材料時進行比較，這是現有的加工標準所不能提供的。這些信息可用於工業應用，延長銑刀壽命並提高加工效率。.

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(Protocol for end mill wear measurement in micro-milling)

Micro-milling yields small accurate parts quickly for electromechanical, aerospace, and medical applications. Due to their small size, micro-end mills wear quickly and unpredictably therefore end mill wear is difficult to measure and is poorly understood, leading to excessive end mill changes and reduced productivity. This paper, therefore, proposes a new protocol for micro-end mill wear measurement to overcome these problems. A strict set of criteria as found in an ISO standard is impractical for micro-milling research. The method herein allows comparisons to be made across materials and situations and detailed are certain criteria that must be fulfilled to achieve this. To evaluate the protocol micro-end mills were used to machine three materials: brass, titanium and Hastelloy; and wear curves produced. Using the described protocol, these wear curves can be analysed similarly to those for larger end mills. Profile analysis of the slots machined provides valuable information about end mill wear where direct measurement is impossible. This new protocol presents a novel method for analysing and reporting end mill wear for micro-end-mills, allowing them to be compared under different machining conditions and/or milling different materials, something not afforded by existing machining standards. The information can then be transferred to industrial applications, extending end mill life and improving process efficiency.

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08/05/2020

好文分享

(航太零件難削材之智慧製造技術)

航空產業向來具備嚴格品質系統認證及高複雜之整合技術，世界各國均以航空產業作為 國家產業技術能力指標。依航空器零件組成成本而言，發動機約佔其中 27%，僅低於機身 的 38%。波音 757 的發動機以鈦合金 (titanium) 38% 與鎳基合金 (nickel) 37% 為主要材料製 成。如無這些材料，噴射引擎將無法操作在所需要的條件。然而，鈦合金、鎳基合金等材 料，在高溫時有良好的機械性質，使得該材料在銑削加工時，銑削力大，散熱速度慢、過高的銑刀溫度、以及材料加工硬化，因而難以有效率的進行銑削加工，特別是在具有複雜扭 轉曲面且薄板特徵的超合金葉輪，其技術難度更深，因此相關航太業者對其銑削製程技術有 迫切的需求。基於此，本文以難削材製程技術為主軸，介紹傳統銑削加工與非傳統加工之發展，並探討智慧製造技術於航太產業之應用。
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(Techniques of Intelligent Manufacturing for Difficult-to-cut Material Applied in Components of Aerospace Industry)

Titanium alloys and nickel-base super alloys are widely in the manufacture of components for aircraft turbine engines because of their ability to retain high strength at elevated temperatures. Because of its high strength, poor thermal diffusion and work hardening, the cutting of these alloys results in the life of tools and efficiency of works for the worse. So the encountered great difficulties in machining difficult-to-cut materials must be solved. To development and application of key technologies be quickly, and create new cutting technology, so as to meet the demand of aerospace industry. The paper will use the development and manufacture of aerospace components with difficult-to-cut material as examples to introduce five-axis machining, hybrid process, rotary ultrasonic-assisted machining process, and on-line measurement basic technique. The research and development of the intelligent manufacturing technologies for aerospace industry also be discussion.
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06/05/2020

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(不鏽鋼的生產與加工特性)

不鏽鋼製造

在用不銹鋼製造產品時，最重要的一點是要記住，要確保製造過程中保留和不破壞不銹鋼的固有特性。
所有不銹鋼的製造都應該只用不銹鋼材料專用的工具進行。使用前必須徹底清潔工具和工作表面。這些預防措施是必要的，以避免易腐蝕的金屬對不銹鋼的交叉污染，以免使製造出來的產品表面變色。
刀具和刀片必須保持鋒利，間隙，例如斜切面刀片之間的間隙必須比碳鋼更緊密。

成型速度
與碳素鋼不同，不銹鋼的工作硬化率意味著在較慢的成形速度下可能會發生更嚴重的變形。對於通常在高速下進行的成型操作，如冷鐓等，建議放慢成型速度。

優勢

除了選擇不銹鋼作為材料的商業原因，如耐熱性和耐腐蝕性，另一個優勢是其製造性能。特別是奧氏體牌號的不銹鋼可以用所有標準的製造方法來製造。有些技術比普通碳鋼更適合於特定的不銹鋼牌號。這一點在嚴重變形過程中得到了很好的證明，如深拉等。
由於不銹鋼的強度和硬化率往往比碳鋼高，因此可能需要對模具和設備進行一些變動。
由於不銹鋼的強度高，可能需要更強力的機器。
由於同樣的原因，一台機器的能力，如斜切斷力可能只需碳鋼能力的60%。
由於成形後的回彈，可能常常需要比碳鋼更大的變形量。例如，在管材製造中，由於需要更高的過彎度，因此需要採用與碳鋼不同的輥組設計。
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(The machining characteristics of stainless steels and fabrication)

St St Fabrication

The single most important thing to remember when fabricating a product from stainless steel is to ensure that the fabrication processes retain and do not compromise the intrinsic properties of stainless steel.
Fabrication of all stainless steels should be done only with tools dedicated to stainless steel materials. Tooling and work surfaces must be thoroughly cleaned before use. These precautions are necessary to avoid cross contamination of stainless steel by easily corroded metals that may discolour the surface of the fabricated product.
Tools and blades must be kept sharp and clearances, for example between guillotine blades, must be tighter than for Carbon steels.

Forming Speeds
Unlike Carbon steels, work hardening rates for stainless steels mean that more severe deformation is possible at slower forming speeds. For forming operations normally performed at high speed, like cold heading, it is recommended that the process is slowed.

Advantages

Apart from the commercial reasons for choosing stainless steel as a material, like heat and corrosion resistance, another advantage is its fabrication properties. The austenitic grades in particular can be fabricated by all standard fabrication methods. Some techniques are more suited to particular stainless grades than normal carbon steels. This is well demonstrated for severe deformation procedures such as deep drawing.
Due to stainless steel tending to have higher strength and work hardening rates than carbon steel, some alteration to tooling and equipment may be required:
A more robust machine may be required due to the high strength of stainless steel.
For the same reason the capacity of a machine, such as a guillotine may be only 60% of its carbon steel capacity.
Greater deformation than used for carbon steels may often be necessary due to spring-back after forming. For example, in tube making a different roll set design to that used for carbon steel will be required as a higher degree of over-bending is necessary.
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04/05/2020

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(數控加工技術在模具製造過程中的應用)

當前在進行模具製造生產領域中，運用數控加工技術，對於模具加工企業的效益提升來說意義重大。採用數控加工技術，不僅給予了企業效率的提升，而且通過加工技術的運用，以及數控加工技術的創新，企業也獲得巨大的收益。作為當前數控加工型製造企業重視的課題，如何強化信息化技術在數控加工技術領域的應用，使得模具加工的方式呈現多樣化發展態勢，如何將傳統的技術難題加以突破，採用局域信息化技術運用在數控加工技術中，如何增強了企業生產效率，而且獲得了巨大的生產效益，都是研究的重點內容。

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(Application of CNC machining technology in the mold manufacturing process.)

Currently in the field of mold manufacturing production, the use of CNC processing technology, on the mold processing enterprises to enhance the effectiveness of the significance. The adoption of CNC machining technology not only gives enterprises an increase in efficiency, but also through the use of processing technology, as well as the innovation of CNC machining technology, enterprises also reap huge benefits. As a topic of importance to the current CNC manufacturing enterprises, how to strengthen the application of information technology in the field of CNC processing technology, making the mold processing mode shows a diversified development trend, how to break through the traditional technical difficulties, the use of local information technology in CNC processing technology, how to enhance the production efficiency of enterprises and obtain great production benefits are all the key research content.

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