With the rapid development of China's automobile industry and mold industry in recent years, automobile panel molds have also developed rapidly in China. Therefore, the gap between the level of some high-end molds in China and foreign countries is shrinking, and the phenomenon of high-end car molds all rely on imports. It is also gradually changing, and the development cycle of new models has been shortened from the past 10 years to 2 to 3 years, all thanks to the improvement of equipment level and processing technology, coupled with the improvement of personnel quality and some new technologies. Applications. However, the automotive panel die directly affects the quality of the final appearance of automotive products, and therefore how to ensure that by selecting the appropriate tool and mold chuck and improve processing quality is particularly important, this tool will cut into the point of view explored.
  Tool bar and blade selection
In today's mold industry, as the pressure on the delivery cycle increases, choosing the best cutting tool is critical. Finishing tools for automotive cover molds are generally indexable inserts using carbide shanks (Figure 1). In addition, depending on the shape of the mold and the processing area, a cutter of 20 mm or 25 mm diameter is generally selected.
Automotive cover drawing die often uses more cast iron materials, such as HT300, QT600, MoCr and MoV, Japan's TGC600, FCD250 and FCD540, as well as German GGG70L commonly used, the general material hardness is about 40HRC, plus car cover The processing area of ​​the mold surface tends to be large, so the selection of the blade is mainly based on the wear resistance.
As a tool supplier, Sandvik Coromant has launched a series of tooling tools for mold processing since 2008. The finishing blades for automotive cover molds have introduced the GC1010 blade material, and the GC1010 blade material is used for Roughened steel roughing to finished milling materials, due to the combination of a thin PVD coating and a fine-grained hard matrix, the blade provides sufficient toughness and wear resistance while also improving the blade edge design. Hardened steel and cast iron provide outstanding processing properties. The benefits of GC1010 material are mainly reflected in the following aspects: the excellent blade line toughness of the blade guarantees better thermal crack resistance and plastic deformation resistance; the tool life is extended, and the reliability and safety of unattended production are guaranteed. It can improve the cutting speed of hardened steel and cast iron, thus improving the production efficiency; when it is required to wear the PVD material, it is the tool of choice for the finishing of automotive cover parts.
Chuck selection
Due to the lengthy finishing time of the automobile cover parts, the shortness is 10~20h and the length is 30~40h. Therefore, in addition to selecting the appropriate blade material, the choice of clamping method can not be ignored. This avoids excessive tool yaw accuracy and results in reduced tool life, so the CoroGrip high-precision power chuck (Fig. 2) from the Sandvik Coromant tool holder series can be used to improve machining accuracy. CoroGrip high-precision power chucks have the following advantages: they can improve the surface quality, and the runout is ≤6μm at 3 times diameter; the tool life can be extended. According to the rule of thumb, for every 10μm increase in the runout, the tool life is shortened by 50%; With virtually no vibration and low noise levels, the runout/balance/torque of each chuck is proven (the chuck is individually balanced to G2.5). High repeatability, clamping force remains unchanged after 15,000 cycles; outstanding performance in heavy-duty roughing applications, exceptionally high clamping forces and rigid structures prevent tool slippage.
The surface quality of the car cover mould has a great relationship with the choice of the tool, and it has a great relationship with the programmed way of the cutter. Maintaining the cutter way of the cutter is the only way to improve the surface quality. Choosing the right machining tool and optimizing the NC programming will significantly improve the quality of the mold, shorten the manufacturing cycle, and directly benefit the manufacturing cost.
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