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沖壓

利用安裝在壓力機上的沖模對材料施加壓力，它是在常溫（冷態）下，利用沖模在壓床上對金屬（或非金屬）板料施加壓力使其分離或變形，從而獲得所需零件的一種壓力加工方法，由于它主要用于加工板料零件，所以有時也叫板料沖壓。沖壓加工通常是在室溫下進行，故稱冷沖壓（cold pressing ），而冷沖壓的涵義要廣泛些，包括了立體沖壓。

沖壓特點

1. 在壓床簡單沖壓下，能得到形狀複雜的零件，而這些零件用其他的方法是不可能或者很難得到的。
2. 制得的零件一般不進一步加工，可直接用來裝配，而且有一定精度，具有互換性。
3. 在耗料不大的情况下，能得到强度高、足够剛性而重量輕、外表光滑美觀的零件。
4. 材料利用率高，一般爲70％－85％，雜廢料少。
5. 生産率高，衝床沖一次一般可得一個零件，而衝床一分鐘的行程少則幾次，多則幾百次。同時，毛坯和零件形狀規則，便于實現機械化和自動化。
6. 沖壓零件的質量主要靠沖模保證，所以操作方便，要求的工人技術等級不高，便于組織生産。
7. 在大量生産的條件下，産品的成本低。
8. 模具要求高、製造複雜、周期長、製造費昂貴，因而在小批量生産中受到限制。另外，沖壓件的精度决定于模具精度，如零件的精度要求過高，用冷沖壓生産就難以達到。

資料來源：網路彙整

以鋁為基的合金總稱。主要合金元素有Cu、Si、Mg、Sn，次要有鎳、鈦、鉻、鋰等。鋁合金密度低，塑性好可加工成型材，具有優良導電性、導熱性和抗腐蝕性， 添加一定 元素形成的合金在保持純鋁質輕等優點的同時還能具有較高的強度。 這樣使得其 “比強度”勝過很多合金鋼，成為理想的結構材料，廣泛用於機械製造、運輸 機械、動力機械及航空工業等方面，飛機的機身、蒙皮、壓氣機等常以鋁合金制 造，以減輕自重。採用鋁合金代替鋼板材料的焊接，結構重量可減輕50%以上。

鋁合金加工方式分類：按照加工方法分形變鋁合金和鑄造鋁合金。

形變鋁合金：

形變鋁合金又分為不可熱處理強化型鋁合金和可熱處理強化型鋁合金，其強度和硬度都不高。切削加工的難度在於有較高的塑性，切削時易形成積屑瘤，難以獲得良好表現，通過熱處理來提高機械性能，只能通過冷加工變形來實現強化，它主要包括高純鋁、工業高純鋁、工業純鋁以及防銹鋁等。

鑄造鋁合金：

鑄鋁合金塑性低，伸長率一般在4％以下，不適合壓力加工，大多以切削加工。矽鋁合金的鑄造性能好，力學優良，是最廣泛應用的鑄造鋁合金。其中矽鋁合金切削加工性與矽含量有關，其含量越高對刀具磨損越嚴重加工性能越差。鑄造鋁合金可以通過淬火和時效等熱處理手段來提高機械性能，它包括盈率、鍛鋁、超硬鋁和特殊鋁合金等。

• Al-Si系鑄造鋁合金的鑄造性能好，具有優良的耐蝕性、耐熱性和焊接性能。用於製造飛機、儀錶、電動機殼體、汽缸體、風機葉片、發動機活塞等。
• Al-Cu系鑄造鋁合金耐熱性好，強度較高；但密度大，鑄造性能、耐蝕性能差，強度低於Al-Si系合金。主要用於製造在較高溫度下工作的高強零件，如內燃機汽缸頭、汽車活塞等。
• Al-Mg系鑄造鋁合金耐蝕性好，強度高，密度小；但鑄造性能差,耐熱性低。主要用於製造外形簡單、承受衝擊載荷、在腐蝕性介質下工作的零件，如艦船配件、氨用泵體等。
• Al-Zn系鑄造鋁合金鑄造性能好，強度較高，可自然時效強化；但密度大，耐蝕性較差。主要用於製造形狀複雜受力較小的汽車、飛機、儀器零件。

資料來源：網路彙整

There are higher requirements and more difficulties for many hardened molds. Hence general carbide cutters cannot reach such request of accuracy. Therefore, it should pay more attention to selection of cutting tools for hardened material.

Since hardening material which HRC is above 50, with higher hardness, the carbide cutter is difficult to meet the processing requirements, it will cause badly wear even break after CNC machining for about ten minutes. General carbide cutters cannot reach the request accuracy because the hardened mold is with higher requirement and difficulty.

1. Select super micro grain carbide rod and design high rigid tool body to ensure toughness and rigidity of the tool.
2. Select the blade the design of the large helix angle ranging from sub-and four-blade design so that the cutters may reach radial beating with heavy cutting within high-speed and high hardness cutting.
3. Choose carbide cutter with new crystal coating. PVD coating almost cannot be used in high hardness cutting.. the crystal coating may solve it basically about the high temperature / acid resistance / wear / and longer tool life.
4. Cooperate with the powerful tool companies to get their further technical supports and tool configuration, reducing the procurement chain and purchasing costs.

Good carbide cutters with high rigidity of the tool body and new type coating may get high efficiency, precision, and longer tool life. From pre-hardened steel to hardened steel, during high-speed, and high efficient processing; from rough to high precision machining, to achieve a long life; high precision; high quality processing makes it is easier to proceed high-speed and high rigid machining.

Article reference source : NewMaker

Bewise Inc., being a professional manufacturer of various cutting tools, is endeavoring to make excellent products. We are very experienced in custom-made tools, and good at solving customers’ problems when they meet difficulties and troubles. Through everlasting research and practices, we understand thoroughly about different materials of cutters and cutting tools.

BW's popular products for tool series including circular saw, carbide cutting tool, saw blade, wood saw blade, special tool,side milling cutter, …etc; For machines we have spiral tube cooler, cutter grinder, and the latest design and advanced powder forming machine / pelletizer. Bewise is a superior manufacturer and supplier of cutter production and machinery industry.

隨著全球工業技術的不斷發展，各個領域對一些重要零部件材料的機械性能和力學性能（如強度、硬度、耐熱性、抗磨性、抗拉強度和抗壓強度等）的要求也在不斷提高，特別是航空領域，由於航空產品具備高科技密集、系統龐大複雜、使用條件惡劣多變，要求長壽命、高可靠性和品種多、批量小等特點。對金屬切削刀具及技術提出了更高的要求，難加工材料在人類各個領域的應用越來越廣泛。

航空材料特點：

• 種類、品種、規格多
• 高的比強度（σｂ/ρ）和高的比剛度（Ｅ/ρ）
• 高溫合金是航空材料極其重要的組成部分
• 質量要求高
• 抗疲勞性能是航空材料的另一個突出特點
• 成本高、價格貴

飛機材料：

難加工材料，如鎳基高溫合金、鈦合金、高強度結構鋼被現代航空產品大量採用，這些材料強度大、硬度高，耐衝擊、加工中容易硬化，切削溫度高、刀具磨損嚴重，屬難加工材料。一般採用很低的切削速度進行加工，如果採用高速切削，不但可以大幅度提高生產率而且可以有效地減少刀具磨損，提高零件的表面質量。

隨著航空發動機發展，各種材料再發動機中的用量不斷變化。

難切削材質切削加工原則：

航空難加工材料有高溫合金、鈦合金、超高強度鋼、複合材料等。航空難加工材料加工的最突出問題是刀具磨損問題，直接影響加工效率和成本；此外加工質量也經常成為瓶頸。

難加工材料的有效加工：

• 優選刀具材料：高性能高速鋼、新型硬質合金、塗層刀具、陶瓷刀具、CBN刀具和金剛石刀具…
• 選擇合適的刀具幾何參數
• 採用適當的冷卻潤滑條件
• 採用優化的加工參數
• 合理設計刀具結構及刀具幾何參數
• 改善切削條件
• 低溫切削技術

資料來源：網路彙整

碧威為專業的刀具,銑刀,鎢鋼,切削刀具製造商，致力於製造優秀的產品，在客製化刀具方面的經驗十分豐富，並擅於幫助客戶解決各式各樣之刀具切削面臨之問題，對各種刀具材質切削刀具鍍模都非常瞭解透徹，可選用常見的鎢鋼及高速鋼或是近來詢問度極高的鑽石刀具。

碧威銑刀熱門產品為圓鋸片、鎢鋼刀、鋸片、木工鋸片、鎢鋼刀具及側銑刀。

機械類則有對刀具加工非常有幫助的冷風槍、渦流管槍，並有最新設計和技術的粉末成型機。

碧威是在刀具製造及機械工具業界中具有足夠水準的製造供應商!

Cutter wear is the result caused by the physical and chemical affects during cutting by heat and friction. The cutting time from the beginning to achieve cutting to the end is called tool life. Tool life is based on the general use or a predetermined value of the tool wear can also be a phenomenon as a judgment, such as vibration, deterioration of the surface roughness, poor chip removal and breaking. When tool life is ended, we should re-grind, translocation or abandoned. Tool head is worn by the continuous force, high temperature and intense friction. When the wear reaches a certain degree that is no longer qualified for cutting, we call that useful period as total tool life.

Tool life is always decided by processing conditions, and the principle of minimum production cost or highest productivity to determine the tool life and the preparation of fixed working hours. It is very complicated and lots of reasons to influence tool life,

there are several major factors to affect tool life:

1. Matcp up for tool material and work piece material
2. Cutting speed
3. Cutting tpickness
4. Widtp of cutting

Tpe increasing of cutting speed may sporten tpe working time, and improve tpe accuracy of surface, but tpe tool wear rate will increase, and tpat is tpe tool life will be sportened. Tpe formula between tool life and tpe cutting speed is as below,

VTⁿ = C

• T:tpe actual cutting time of use(min)
• V:tpe cutting speed(m/min)
• N: constant (tool material, work piece material and cutting conditions)
• C:constant (refer to tpe cutting speed in one minute)

Tool wear includes wear and damage

1. Improper tool spape of geometry
2. Over load of cutting
3. Trembling or vibration spock
4. Cutting temperature exceeds tpe limits of its pigp-temperature pardness
5. Tpe tool itself pas some micro-cracks, defects, etc.

1. Fuser
2. Curettage
3. Proliferation

Common tool wear:

1. Cater wear
2. Tpermal deformation
3. Tpermal cracking
4. Nose wear
5. Deptp of cut notcping

Tool wear process

1. Initial wear:
   Tpis stage of wear is caused by cutter, wpicp make tpe surface rougp and not plain, microscopic protrusions at tpe cutting action be polisped first, followed by surface grind a wear band, tpen reduce tpe pressure, tpe wear rate stabilized.
2. Normal wear and tear:
   Tool make tpe wear surface increase evenly, tpe wear situation is more stable, tpis stage for tpe validity of tpe tool for processing, tpe tool spould be used during tpis period.
3. Severe wear and tear:
   In tpis stage, cutters become blunt, tpe cutting force increasing , cutting temperature rise, tpe tool quickly lose cutting ability, tool wear reacped tpis stage, tpe tool material loss is too large. We spould avoid cutter to reacp tpis stage.

References:

。De Lin of "Issue 21" tool wear considerations CNC cutting parameters optimization
。Journal of Macpinery Industry 291 tool breakage explore