Hardened alloy milling cutters, due to their small shape tolerances, are widely used. However, as they cannot be directly replaced with blades, most of them are scrapped after chipping, significantly increasing processing costs.
Processing Material Properties
During the cutting of titanium alloys, due to their poor thermal conductivity, chips tend to adhere near the tip and edge of the tool or form built-up edges, creating high-temperature zones on the front and rear faces near the tip, leading to the loss of tool hardness and increased wear. In continuous cutting under high-temperature conditions, the adherents and welds are subjected to the impact of subsequent processing, and in the process of being forcibly removed, they carry away some of the tool material, causing tool damage and breakage. Additionally, when the cutting temperature reaches above 600°C, a hardened layer forms on the surface of the workpiece, exerting a strong abrasive effect on the tool. Titanium alloys have a low elastic modulus and significant elastic deformation, with a large amount of surface rebound near the rear face, resulting in a large contact area between the machined surface and the rear face, leading to severe wear.
2. Normal Wear
During normal production and processing, severe blade wear occurs when the excess of continuous milling titanium alloy parts reaches 15mm to 20mm. Continuing to mill results in low efficiency and poor surface finish of the processed parts, which fails to meet production and quality requirements.
Improper operation
During the production and processing of titanium alloy casting boxes and lids, improper clamping, unsuitable cutting depth, excessive spindle speed, and inadequate cooling can lead to blade chipping, damage, and breakage. These defective milling cutters, aside from being unable to effectively mill, can also cause surface defects such as concave machining surfaces during the cutting process due to "biting the blade." This not only affects the machining quality of the milling surface but can also result in the scrapping of the workpiece in severe cases.
