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Development and Application of Ultra-Hard Cutting Tool Solutions

Development and Application of Ultra-Hard Cutting Tool Solutions

Superhard cutting-tool materials refer to natural diamond, as well as synthetic diamond and cubic boron nitride (CBN) whose hardness and performance are comparable. Given the high cost of natural diamond, industrial applications of superhard cutting tools typically rely on synthetic polycrystalline diamond, polycrystalline cubic boron nitride, and their composite materials. Let us now explore the development and applications of superhard cutting-tool solutions.

12

2022

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05

Common Issues and Solutions for Ultra-Hard Cutting Tool Solutions

Common Issues and Solutions for Ultra-Hard Cutting Tool Solutions

In deep-hole machining, carbide cutting tools often encounter challenges such as dimensional accuracy of the workpiece, surface quality, and tool life. Reducing or eliminating these issues is a pressing concern that requires immediate attention. Let’s now explore the common problems associated with carbide cutting-tool solutions and the corresponding mitigation measures.

07

2022

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05

What are the precautions for high-pressure cooling systems in deep-hole drilling?

What are the precautions for high-pressure cooling systems in deep-hole drilling?

What are the challenges of deep-hole drilling with a high-pressure cooling system, what types of deep-hole drill bits are available, and what factors should be considered when selecting and choosing a deep-hole drill bit? What machining methods are used in deep-hole drilling with a high-pressure cooling system, and what precautions should be taken during deep-hole machining? This article covers all of these topics—hopefully it will be helpful to you!

03

2022

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05

Essential Knowledge Points for High-Pressure Cooling Systems in Deep-Hole Drilling

Essential Knowledge Points for High-Pressure Cooling Systems in Deep-Hole Drilling

The nozzle component for deep-hole drilling, featuring a high-pressure cooling system, has a total machining length of 105 mm, a hole diameter of φ6 + 0.12 mm, a wall thickness of 2 mm, a surface roughness of Ra 3.2 μm, and a depth-to-diameter ratio of 17:1. It is made of GH4169, a material that is difficult to machine.

29

2022

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04

Coolant Control in High-Pressure Cooling Systems for Deep-Hole Drilling

Coolant Control in High-Pressure Cooling Systems for Deep-Hole Drilling

Coolant plays a critical role in the high-pressure cooling system for deep-hole drilling, and modern advanced systems employ cooling strategies that are broadly analogous to those used to control the machine spindle or shaft. Careful management of coolant pressure, filtration, temperature, and flow rate is essential for optimizing the deep-hole drilling process.

25

2022

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04

Intelligent Inspection for Precision Machining of Automotive and Aerospace Components

Intelligent Inspection for Precision Machining of Automotive and Aerospace Components

Precision Intelligent Inspection Precision component intelligent inspection is primarily geared toward industries such as aviation, aerospace, automotive, electronics, and shipbuilding. Leveraging the technological expertise of Nanjing University of Aeronautics and Astronautics, we have established an integrated “industry–academia–research–application” R&D system. Our mission is to conduct fundamental research, drive technological innovation, provide technical services, and facilitate the commercialization of results in the fields of online precision component inspection technologies and intelligent turnkey equipment, thereby delivering core technologies and equipment that support the flexibilization, automation, integration, and intelligence of production, manufacturing, and assembly processes. Centered on internationally advanced high-precision online measurement technology, we develop and manufacture automated online measurement systems for precision components, primarily for the real-time inspection of critical automotive engine parts such as cylinder blocks, cylinder heads, crankshafts, connecting rods, and camshafts. Supported by industrialization platforms including the Jiangsu Provincial Academy of Industrial Research’s Institute of Precision and Micro-Manufacturing Technology and the NUAA Pukou Advanced Manufacturing Technology Research Institute, our products meet the latest “intelligent manufacturing” requirements outlined in “Made in China 2025” from both precision and online perspectives, enabling full online inspection of automotive engine components. Guided by the vision of “Leading Precision Measurement, Creating Chinese Precision,” our business unit builds upon an entrepreneurial team and leverages the technological strengths of the Provincial Academy of Industrial Research and the NUAA Pukou Advanced Manufacturing Technology Research Institute to jointly achieve the industrial application of these technologies and maximize both their technical and societal value. Product Introduction: Online Measurement Technology and Turnkey Systems for Precision Part Machining As the aerospace and automotive manufacturing sectors continue to advance toward higher precision and greater intelligence, high-precision, intelligent online inspection technologies and equipment have become a critical bottleneck. Our product breaks through the following key technological barriers: (1) We have developed pressure-sensitive ultra-high-precision detection technology that overcomes the technical challenges of non-contact, high-precision measurement, achieving a measurement accuracy of 0.1 μm; (2) We have engineered multi-channel synchronous high-speed sampling technology with automatic compensation, addressing the issue of poor dynamic performance in multi-point data acquisition and attaining a measurement resolution of 0.05 μm; (3) We have solved the challenge of high-speed online inspection for complex, eccentric shaft-type components by developing high-precision, follow-up detection technology, reducing the maximum measurement time to less than 45 seconds and fully meeting the demands of online measurement; (4) We have created integrated detection technology for dimensional errors, geometric errors, and physical parameters, increasing inspection efficiency by more than 30%; (5) We have developed multi-parameter, high-precision, small-range, rapid, high-frequency detection combined with real-time fitting technology, enabling the simultaneous measurement of more than four parameters within a small range of 2 mm, with a sampling frequency exceeding 1,000 samples per second and a sampling accuracy of 0.2 μm. This product finds broad applications in the online measurement of core precision components throughout the machining processes in the automotive and aerospace industries.

12

2022

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02

How is the positioning accuracy of the rotary axis measured on a cradle-type five-axis machining center?

How is the positioning accuracy of the rotary axis measured on a cradle-type five-axis machining center?

Precision Measurement of the Rotary Axis in a Cradle-Type Five-Axis Machining Center

02

2021

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12

ArCut X: a highly efficient milling cutter for machining curved and spherical surfaces.

ArCut X: a highly efficient milling cutter for machining curved and spherical surfaces.

ArCut X is the ultimate enabler for highly efficient finishing with outstanding surface quality. Are you using ball-end mills to finish flat surfaces? Have you ever wondered why the machining time is so long? FRAISA has introduced the latest ArCut X milling cutter to help you overcome this challenge. ArCut X is a family of tapered end mills whose curved cutting edges feature a radius of up to 1,000 mm. Thanks to this exceptionally large radius, it is possible to increase the stepover without compromising the theoretical residual height, resulting in high-precision surfaces with excellent surface finish—and significant savings in finishing time. The ArCut X cutter also incorporates a perfectly spherical profile, while retaining all the advantages of a robust ball-end mill. In this way, FRAISA’s innovative ArCut X concept combines top-tier finishing performance with near-perfect surface quality, making it an exceptionally compelling solution for precision finishing of flat surfaces. Key benefits: Lower costs: Excellent finishing performance and rapid machining Lower tool costs: The longer cutting edge design reduces wear, and the tools can be regrinded and recoated High quality: The tool’s outstanding contour accuracy—contour tolerances of ±5 μm ensure precise workpiece geometry Applications: Precise, validated cutting parameters; a carefully designed product range covers a wide spectrum of applications FRAISA ToolExpert ArCut X: Enables quick and easy access to cutting parameters ReTool® service: Tool regrinding and coating Applications Leveraging the ArCut X concept, FRAISA offers multiple versions of tapered end mills that cover a broad range of finishing processes. Combined with various tool features, these technologies make the tools suitable for machining a wide variety of materials. FRAISA ToolExpert cutting-parameter software makes ArCut X end mills even more attractive All online application data have been rigorously tested and validated, ensuring the effective milling performance of ArCut X end mills. The newly developed FRAISA ToolExpert ArCut X now reliably helps users select the most suitable end mill from the ArCut X series based on the workpiece material and application. Its clear, menu-driven interface allows users to easily choose the material, application, ArCut X end-mill type, and whether to opt for coated or uncoated options. Moreover, when using FRAISA ToolExpert ArCut X, the software recommends appropriate cutting parameters for the selected end mill. Since it is specifically designed for ArCut X end mills, it fully exploits the capabilities of these tools. Record-breaking finishing Using ArCut X end mills requires a powerful CAM solution that can fully harness their geometric potential. Most leading CAM vendors have already developed dedicated modules to maximize the advantages of these tapered arc-shaped cutters and simplify programming. The larger-radius arc-shaped cutting edge ensures exceptionally high surface quality even at relatively large stepovers when machining flat surfaces. In this way, compared with ball-end mills, up to 90% of finishing time can be saved! Advantages: Shorter production time Up to 90% reduction in machining time Longer tool life Best surface finish Highest machining efficiency Wide range of applications: Mold manufacturing, aerospace, tire molds, turbine blades and impellers ArCut X ball-end mills for finishing steep surfaces and fillets ArCut X round-nose end mills for roughing corners and finishing steep areas ArCut X spherical and round-nose end mills for finishing flat bottoms

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2021

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