Cutting force is the force applied by the tool to the workpiece during turning. Its size not only determines the degree of deformation of the workpiece, but also directly affects the wear rate of the tool, machining efficiency and machining quality. In the precision machining of sprinkler stainless steel, excessive cutting force may cause deformation of the workpiece, increase surface roughness, and even cause serious problems such as tool chipping and fracture. On the contrary, too small cutting force may reduce machining efficiency and increase machining costs. Therefore, reasonable control of cutting force is the key to ensuring the quality of precision machining of sprinkler stainless steel.
Cutting parameters, including feed speed, cutting depth, spindle speed, etc., are the main factors affecting cutting force. Scientifically setting these parameters is the key to controlling cutting force and ensuring machining quality.
Feed speed: Feed speed refers to the speed at which the tool moves relative to the workpiece. In the precision machining of sprinkler stainless steel, the selection of feed speed should comprehensively consider factors such as material hardness, tool wear resistance, and machining accuracy requirements. Generally speaking, for stainless steel materials with higher hardness, a lower feed speed should be selected to reduce cutting force and tool wear.
Cutting depth: Cutting depth refers to the maximum depth that the tool cuts into the workpiece. The selection of cutting depth also needs to weigh the relationship between processing efficiency and cutting force. In stainless steel processing, excessive cutting depth will increase cutting force and tool wear, while too small cutting depth may reduce processing efficiency. Therefore, the appropriate cutting depth should be selected according to the specific processing situation.
Spindle speed: Spindle speed refers to the rotation speed of the lathe spindle. The selection of spindle speed directly affects the cutting force and processing efficiency. In stainless steel processing, appropriately increasing the spindle speed can reduce the cutting force, but too high a speed may cause increased tool wear and even cause machine vibration. The spindle speed should be reasonably set according to factors such as tool material and geometry, workpiece material characteristics, etc.
Tool material and geometry are another important factor affecting cutting force. Choosing the right tool material and geometry is of great significance for controlling cutting force and improving processing quality.
Tool material: In the precision processing of sprinkler stainless steel, commonly used tool materials include cemented carbide, ceramics, cubic boron nitride (CBN), etc. These materials have excellent wear resistance, heat resistance and impact resistance, and can meet the high requirements of stainless steel processing. Carbide tools are widely used because of their low cost and high processing efficiency; ceramic tools have higher heat resistance and wear resistance, and are suitable for high-speed cutting; and CBN tools are ideal for processing difficult-to-process materials such as stainless steel due to their extremely high hardness and wear resistance.
Tool geometry: The geometry of the tool, including the rake angle, back angle, cutting edge shape, etc., has an important influence on the size and distribution of cutting forces. In the precision machining of sprinkler stainless steel, the appropriate tool geometry should be selected according to factors such as machining requirements, material properties and tool materials. For example, for stainless steel materials with higher hardness, tools with larger rake angles and smaller back angles should be selected to reduce cutting forces and tool wear; while for sprinkler parts that require high-precision machining, tools with sharp cutting edges and smaller rake angles should be selected to improve machining accuracy and surface finish.
Cutting fluid plays a role in cooling, lubricating and cleaning in the precision machining of sprinkler stainless steel. Choosing the right cutting fluid is of great significance for controlling cutting force, improving processing quality and extending tool life.
Types of cutting fluid: Cutting fluids are mainly divided into two categories: water-based cutting fluids and oil-based cutting fluids. Water-based cutting fluids have good cooling and cleaning properties, and are suitable for high-speed cutting and heat-generating processing processes; while oil-based cutting fluids have better lubrication and rust prevention properties, and are suitable for processing processes with high processing precision requirements and easy to generate friction heat. In the precision processing of sprinkler stainless steel, the appropriate type of cutting fluid should be selected according to factors such as processing requirements, material properties and cutting parameters.
Application of cutting fluid: The application methods of cutting fluid include spraying, immersion and spraying. In the precision processing of sprinkler stainless steel, the appropriate cutting fluid application method should be selected according to the processing equipment and processing requirements. For example, for high-speed cutting processes, spraying or spraying should be used to ensure that the cutting fluid can fully reach the cutting area and play a good cooling and lubrication role; while for sprinkler parts with high processing precision requirements, immersion should be used to ensure that the cutting fluid can fully penetrate between the workpiece and the tool to reduce friction and wear.
In the precision machining of sprinkler stainless steel, the monitoring and optimization of machining quality are equally important. By real-time monitoring of cutting force, vibration, temperature and other parameters during the machining process, timely detection and solution of problems can ensure the stability and reliability of machining quality.
Cutting force monitoring: By installing a cutting force sensor and real-time monitoring of cutting force changes during machining, problems such as tool wear and workpiece deformation can be detected in time, and corresponding adjustment measures can be taken.
Vibration monitoring: Machine tool vibration is one of the important factors affecting machining quality. By installing a vibration sensor and real-time monitoring of machine tool vibration, problems such as machine tool failure or unreasonable machining parameters can be detected in time, and corresponding adjustments and optimizations can be made.
Temperature monitoring: The heat generated during cutting may cause workpiece deformation and tool wear. By installing a temperature sensor and real-time monitoring of temperature changes during machining, cutting parameters and cutting fluid flow can be adjusted in time to ensure the stability and reliability of machining quality.
