20KHz 1Non-contact Ultrasonic Milling equipment for Metal processing
Milling is the process of machining using rotary cutters to remove material by advancing a cutter into a work piece. This may be done varying direction on one or several axes, cutter head speed, and pressure. Milling covers a wide variety of different operations and machines, on scales from small individual parts to large, heavy-duty gang milling operations. It is one of the most commonly used processes for machining custom parts to precise tolerances.
Milling can be done with a wide range of machine tools. The original class of machine tools for milling was the milling machine (often called a mill). After the advent of computer numerical control (CNC) in the 1960s, milling machines evolved into machining centers: milling machines augmented by automatic tool changers, tool magazines or carousels, CNC capability, coolant systems, and enclosures. Milling centers are generally classified as vertical machining centers (VMCs) or horizontal machining centers (HMCs).
The integration of milling into turning environments, and vice versa, began with live tooling for lathes and the occasional use of mills for turning operations. This led to a new class of machine tools, multitasking machines (MTMs), which are purpose-built to facilitate milling and turning within the same work envelope.
Milling machines are very versatile. They are usually used to machine flat surfaces, but can also produce irregular surfaces. They can also be used to drill, bore, cut gears, and produce slots. The type of milling machine most commonly found in student shops is a vertical spindle machine with a swiveling head.
Milling is a cutting processing method in which the rotation movement of the milling cutter is the main movement, and the milling cutter or the workpiece is used as the feed movement. Its unique features are:
1. It adopts multi-edge tool processing, cutting edge alternately, the tool cooling effect is good, and the durability is high.
2. Milling processing has high production efficiency and wide processing range. Various milling cutters can be used on ordinary milling machines to complete processing planes (parallel planes, vertical planes, inclined planes), steps, grooves (right-angle grooves, V-shaped grooves, T-slots, dovetail grooves and other special-shaped grooves), special-shaped surfaces and other processing tasks. Coupled with the use of milling machine accessories such as indexing heads, it can also complete the milling of spline shafts, screw shafts, gear clutches and other workpieces.
3. Milling processing has high processing accuracy, its economic processing accuracy is generally IT9-IT7, and the surface roughness Ra value is generally 12.5-1.6um. The precision milling precision can reach IT5, and the surface roughness Ra value can reach 0.20um.
Because of the above characteristics of milling processing, it is particularly suitable for the processing of complex parts such as molds, and occupies a very important position in industries such as mold manufacturing. With the rapid development of numerical control technology, the role of milling in mechanical processing is becoming more and more important, especially in the processing of various special-shaped curved surfaces, which has advantages that other processing methods cannot match. At present, on the five-axis CNC milling machining center, even the entire artwork can be copied continuously and efficiently.
Milling is one of the most commonly used machining methods in CNC milling machine machining, mainly including plane milling and contour milling, which can process and tap parts. Suitable for CNC milling parts such as box and surface parts.
(1) Plane parts. The feature of this type of parts is that each processing surface is flat or can be expanded into a flat surface. At present, most of the parts processed on CNC milling machines are used for noodle parts. Planar parts are the simplest type of CNC milling processing objects. Generally, they can be processed only with the two-coordinate linkage of the three-coordinate CNC milling machine (ie, two-axis and half-coordinate machining).
(2) Variable bevel parts. Parts where the angle between the processing surface and the horizontal plane changes continuously are called variable bevel parts. Machining variable bevel angle parts{zh0} adopts four-axis or five-axis control milling machine swing angle processing, if there is no such machine tool, it can also use two-axis semi-control line cutting method on three-axis control milling machine for approximate processing. The machine tool can also be approximated by a two-axis semi-controlled line cutting method on a three-axis controlled milling machine.
(3) Surface parts. Parts whose processing surface is a space surface are called surface-type parts. The machined surface of the curved surface parts and the milling cutter are always in point contact, and the three-axis CNC milling machine is generally used.
| Item |
Parameter |
| Abrasive |
Boron carbide, aluminium oxide and silicon carbide |
| Grit size(d0) |
100 - 800 |
| Frequency of vibration (f) |
19 - 25 kHz |
| Amplitude of vibration (a) |
15 - 50 µm |
| Tool material |
Soft steel titanium alloy |
| Wear ratio |
Tungsten 1.5:1 and glass 100:1 |
| Gap overcut |
0.02-0.1 mm |
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