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Increase stainless steel processing efficiency by 50%
Date of issue：2022-06-24 Number of visits：504 Publishing author：BangBaoWuJin
When milling stainless steel, the compromise between milling efficiency and service time is the decisive factor affecting economy. A mixing equipment company tested its cutting process and found a way to significantly improve the milling efficiency of hard and tough stainless steels.
On the raw material of forged ring bag with material of 1.4462, a copying cutter is used to mill the square receiving hopper for the mixed shovel. Then, the side itD is milling with a right-angle milling cutter.
Paderborn-based Loedige-Gruppe is one of the world's largest suppliers of mixing and beneficiation technology. The cutting of each component must be economical. In the exploration of technical improvement, the company pays special attention to the milling of stainless steel bags with chemical resistance and high temperature resistance. In this type of operation, you need to achieve a large amount of cutting in a very short time, but also achieve a long tool life. Therefore, the HSS and indexable milling cutters used in the past can be replaced by longer life and more reliable performance of the cutter. For the first phase of the Ingersoll milling test, a common 1.4462 steel bag was selected for the centrifuge shaft with a length of 10m and a diameter of 250mm. A total of 10 steel bags can carry mixing spades shaped according to the corresponding mixture. Two specially shaped circular steel bags seal the shaft from both sides. Square supports of the same size for the mixing bucket must be milled into both bags. HSS sleeve end mills with diameters of 50mm have been used to date, but the results achieved in terms of cutting efficiency, surface quality and service life have been modest.
The selected 2J1C Ingersoll right-angle face milling cutter with five indexable blades of 90o and a diameter of 50mm can achieve a cutting capacity of 84.24m3/min, about 6% higher than the competition. This achievement was attributed to the successful application of a cutting speed of 53m/min, a feed rate of 0.1mm/ tooth, a depth of 10mm and a cutting width of 50mm. Through three feeds, the bag receives wet milling on the reverse side.
Indexable blade of copying cutter has excellent heat resistance:
The longer service life compared to the competition's right-angle milling cutter, the main stainless steel machining time is reduced by 50% when using Ingersoll right-angle milling cutter for three parts under approximately the same cutting conditions, resulting in an additional 6h of equipment capacity. The most important aspect of Loedige's future plans is the high temperature tolerance of the sleeve end mill during wet milling. With good cutting Angle and sharp blade, the feed can reach 10mm when machining stainless steel.
As the last step, two 5W7K sleeve profile milling cutters were tested. Firstly, a milling cutter with a diameter of 66mm was used to hollow out the steel bag. The first tool adopts the standard track feed, and then the following data and synchronous milling out the shape: cutting speed 120m/min, cutting depth 2mm, cutting width 50mm, each tooth propulsion 0.5mm.
In the first test, the bag was subjected to fifteen wet feeds, followed by ten dry milling. In the meantime, knife bumps and slight free surface wear can occur after a long period of operation, so all steel bags should be wet-machined in future. Then a profile milling cutter of 80mm diameter with six valid blades was used. At the same cutting value, the cutter performs 16.7min of dry milling on the plane above the steel bag, which significantly improves the service life of the cutter compared to the competitive disc cutter.
On the raw material of forged ring bag with material of 1.4462, a copying cutter is used to mill the square receiving hopper for the mixed shovel. Then, the side itD is milling with a right-angle milling cutter.
Paderborn-based Loedige-Gruppe is one of the world's largest suppliers of mixing and beneficiation technology. The cutting of each component must be economical. In the exploration of technical improvement, the company pays special attention to the milling of stainless steel bags with chemical resistance and high temperature resistance. In this type of operation, you need to achieve a large amount of cutting in a very short time, but also achieve a long tool life. Therefore, the HSS and indexable milling cutters used in the past can be replaced by longer life and more reliable performance of the cutter. For the first phase of the Ingersoll milling test, a common 1.4462 steel bag was selected for the centrifuge shaft with a length of 10m and a diameter of 250mm. A total of 10 steel bags can carry mixing spades shaped according to the corresponding mixture. Two specially shaped circular steel bags seal the shaft from both sides. Square supports of the same size for the mixing bucket must be milled into both bags. HSS sleeve end mills with diameters of 50mm have been used to date, but the results achieved in terms of cutting efficiency, surface quality and service life have been modest.
The selected 2J1C Ingersoll right-angle face milling cutter with five indexable blades of 90o and a diameter of 50mm can achieve a cutting capacity of 84.24m3/min, about 6% higher than the competition. This achievement was attributed to the successful application of a cutting speed of 53m/min, a feed rate of 0.1mm/ tooth, a depth of 10mm and a cutting width of 50mm. Through three feeds, the bag receives wet milling on the reverse side.
Indexable blade of copying cutter has excellent heat resistance:
The longer service life compared to the competition's right-angle milling cutter, the main stainless steel machining time is reduced by 50% when using Ingersoll right-angle milling cutter for three parts under approximately the same cutting conditions, resulting in an additional 6h of equipment capacity. The most important aspect of Loedige's future plans is the high temperature tolerance of the sleeve end mill during wet milling. With good cutting Angle and sharp blade, the feed can reach 10mm when machining stainless steel.
As the last step, two 5W7K sleeve profile milling cutters were tested. Firstly, a milling cutter with a diameter of 66mm was used to hollow out the steel bag. The first tool adopts the standard track feed, and then the following data and synchronous milling out the shape: cutting speed 120m/min, cutting depth 2mm, cutting width 50mm, each tooth propulsion 0.5mm.
In the first test, the bag was subjected to fifteen wet feeds, followed by ten dry milling. In the meantime, knife bumps and slight free surface wear can occur after a long period of operation, so all steel bags should be wet-machined in future. Then a profile milling cutter of 80mm diameter with six valid blades was used. At the same cutting value, the cutter performs 16.7min of dry milling on the plane above the steel bag, which significantly improves the service life of the cutter compared to the competitive disc cutter.
