Development of cutter materials is actually the process of improving their heat resistance, abrasion resistance, cutting speed and surface machining quality constantly.
Currently, ceramic material has wider application scope and can machine several materials; it is applied to high speed turning process mostly and also applied to grooving and milling processes. Each ceramic material has special property. With proper application, it can give full play to production efficiency.
When and how to use ceramic materials are very important for success of machining. Comparing with carbide, ceramic material has higher hardness, heat hardness and abrasion resistance and better chemical stability and anti-oxidation capability. Therefore, ceramic cutter has become a main stream for developing cutters in aviation and aerospace industries.
Research, development and promotion of Fulaike ceramic milling cutters conform to industrial development trend and become another innovation of self-improvement.
▴Part machining ▴
The key of ceramic cutter is cutting heat and the core of cutting parameter is heat balance. Relying on high speed dry type cutting, ceramic cutter increases cutter tip temperature to about 1000℃ instantaneously to soften workpiece material and turn the material that is hard to be cut to the one that is easy to be cut, realizing super efficient machining. The most significant factor affecting cutting parameter is hardness and surface of the material.
To obtain the best cutting condition, it is necessary to balance the relation between linear speed and feed carefully. Linear speed and feed need to be increased or decreased in proportion simultaneously; otherwise, excessively high or low cutting heat will cause shortened or invalid cutter service life.
With silicon nitride ceramics as its base material, Fulaike ceramic milling cutter features higher strength and stronger breaking tenacity. It can reduce abrasion effectively to realize super high machining efficiency.
It shall be noted that thick cutting chip with big feed provide greater heat radiation effect but it is cooler and harder; thin cutting chip with small feed has no sufficient heat absorption capability, easy to be overheated. The most proper linear speed and feed need to be figured out for each hardness and surface of the workpiece material to get the best heat balance
▴Recommended cutting condition▴
|Heat resistant alloy nickel alloy®718类GH4169 high temperature alloy type high hardness steel（＞HRC55）etc.||Heat resistant alloy nickel alloy®718类GH4169 high temperature alloy type high hardness steel（＞HRC55）etc.|
|Outer diameter DC（mm）||Cutting speed （m/min）||Feed of each blade||Cutting depth ap（mm）||Cutting width ae（mm）||Outer diameter DC（mm）||Cutting speed （m/min）||Feed of each blade（mm/toot）||Cutting depth ap（mm）|
|Lateral machining (dry cutting)||Transverse machining (dry cutting)|
It shall be noted that flake peeling from front cutter face periphery in machining results from tiny crack spreading in the ceramics caused by cutting pressure. Normally, abrasion of the type of cutters will not damage cutter property. And surface finish is not the main consideration factor in rough machining. The tiny peeling will generate new sharp cutter tip edge and the cutter can continue working in rough machining under the status. But fine machining has requirements for surface finish and other cutters need to be used.
Main shaft power ：>10KW
Feed speed ：5157mm/min
Cutting depth: ap=7mm (climb milling)
Machining mode: cycloid milling
Cooling mode: dry type
Recommended air cooling (not cooling cutter, for cooling fixture and removing chip. Cooling fixture is beneficial for keeping fixture accuracy.)
1.Possess 4-blade type for cavity machining and 6-blade ceramic milling cutter for efficient lateral milling
2.Optimize spiral angle, preventing cutter from being pulled out under the cutting condition of high speed and big feed
3.Adopt sharp blade type that suits heat resistant alloy machining best and improve break resistance under large load machining
4.Heat resistant and high strength ceramic material with very strong universality
Hydraulic chuck is recommended. Machining status is unstable when spring chuck is used
It is unnecessary to remove sticking substance on the blade before continuing machining. Sticking substance can be removed by cutting heat
Machining margin is set to above 0.3. Deteriorative layer may be generated after rough machining. Reserve at least 0.3 margin for fine machining. After high temperature threading, residual material is softened to benefit application of fine machining cutter.
Continuous machining is recommended because intermittent machining is easy to generate blade break, which may lower cutter service life.
Full-shield machine tool must be used and any combustible shall be removed from the machine tool
Titanium alloy is prohibited, which will bring very high risk and may cause a fire