Characteristics of precision miniature cutting tools

Four major cutting method:

1. Precision micro turning
2. Precision micro milling
3. Precision micro fly cut
4. Precision micro drilling

There are precision micro turning tools,flat end mills, ball end mill, throwing cutter, and drills according to these applications. The working conditions, friction, impact, and cutting resistance are much worse because of the limitation of size, which is different from normal spec tools.

Basic requirements for miniature cutters:

1. Small work piece and micro machining partIn order to fit the characteristics of tiny machining, high machining accuracy and avoid interference between the work piece and the cutter, the whole work piece and the machining scale must be synchronized reduced.
2. Sharp cutting edgeUnder micro cutting conditions, in order to achieve a very small amount of material removed, the depth of cut and feed rate is usually in the micron level, the cutting edge should be sharp enough.
3. Good quality of surfaceSurface quality influences the performance of the micro-cutting tools a lot, poor surface quality will not only increase the frictional resistance and lead to the deterioration while fine cutting, but also weaken the toolstrength.
4. Good quality of surfaceRotary tools like the small diameter of end mills and drills, micro-cutting is carried out under high spindle speed.The cutting part of cutters should have sufficient strength and dynamic characteristics, which are able to afford the high impact load.
5. Rigid, anti-deformation abilityTo ensure working accuracy, miniature cutters should have higher rigidity to reduce the deformation and rebound under cutting force.
6. Good wear resistance, average wear processThe cutting part of the micro cutting tools should have enough hardness to ensure its abrasion resistance.Blunt cutter will not only affect its machining accuracy, but also happen processing glitches which will bring difficulty of surface finishing.
7. High accuracy of dynamic balanceThe run out feed rate of micro cutter is significantly greater than cutting for normal size… Under high spindle speed, the cutting edge between the cutting load is very uneven, the cutting force fluctuation is serious, the tip trajectory and accuracy of processing, the tiny end mills, drills and other rotary tool should have high accuracy of dynamic balancing.
8. Accurate and reliable tool clampingSmall rotary tool installation error is the main factor to influence the machining accuracy and reliability. The tool clamping system should have high contact rigidity, accuracy of repeating position, and good speedy locking.

Material of micro cutters

It is a very important mean to choose the advanced and applicable tool material, which may ensure the whole performance of micro tools .. The ideal materials for miniature cutters are diamond, fine grain and ultra-fine grain carbide.

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.

 

擴散粒子 – BW產品

一般擴散粒子(Diffusion beads)包括有機材質之壓克力樹脂(PMMA)或聚苯乙烯(PS)或共聚PMMA-PS等多種高分子材質，具真圓狀的外型或多孔、絨毛、中空等行裝‧配合光學膜或其他用途，他可調控折射率、著色率、分散性、流動性、光反射性及彈性、接著性等。主要應用為LED背光模組擴散膜之光擴散劑及LED燈具擴散膜及其他光學塗層等。

 

Characteristics and processing differences of cutting tools

Characteristics and processing differences of the four kinds of cutting tools?

1. Plain Milling Cutter：

   Plain Milling Cutter is the most commonly used tool in a horizontal milling machine. Plain Milling Cutter’s shape is like disc or cylindrical, which has blades on the outer circumference of the cutter for milling the plane which parallel to the cutter axis. The blade shapes include straight and helical blade-shaped. Generally helical blade shape is more commonly used. If the blade width is less 20mm, it is only suitable for light milling and milling hard materials because of its multi blades and small chip slots; if the width is over 20mm, it’s often designed as helical teeth in order to reduce the shear force and prevent vibration during milling, with fewer blades, so the chip slot is larger which is suitable for heavy milling and cutting soft materials.

2. End Mill：

   Such cutters have a flute in the circumferential surface and the end for milling flat, face, shoulder angle and groove .There are straight shank, taper shank, straight flute, helical flute, double flute, multi-flute, and so on.

3. Side Milling Cutter：

   The shape of the side milling cutter is similar to the straight flute face cutter. Except the shape and function of end mills, its side also has cutting edge, which can milling the face and the side of work piece. Edge shape can be divided into straight teeth, spiral teeth and staggered teeth. Staggered teeth may be offset against each other and reduce vibration during machining, which is suitable for heavy milling.

4. Face Milling Cutter：

   Face milling cutter is a disc-shaped, with cutting blades around the body and the side face. Such cutter is specialized in cutting larger plane. The blade face is wider, and the cutter body is made of general tool steel, then embedded high-speed steel or carbide blade.

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.

 

What’s the difference among tungsten carbide, tungsten steel cutter, and super hard alloy cutter?

There are many kinds of different milling cutters. It may be divided into three categories as below according to its applications.

In fact, they are saying the same tool. The component is tungsten carbide (WC) and took part in the P type, M type, and K type. Micro grain carbide tool is made of tungsten carbide and adding some elements to to increase the hardness and abrasion resistance. Super hard alloy cutting tools is named by Japanese, which is also tungsten carbide cutter.

P, M, and K types are divided according to the different turning material.

• P-type (most common) is suitable for turning mild steel, medium carbon steel, high carbon steel ….
• K type is suitable for turning of high hardness materials such as cast iron, high-speed steel (HSS) or heat treated material….
• M type is between the P and, K types which is suitable for difficult material or higher tensile strength material such as tin, hydraulic rod ….

Drill cutter and lathe tool depend on cutting volume.

HSSis suitable to produce drill bit cutters. Tungsten carbide is suitable for small cutting amount, good surface roughness or cutting high hardness material.

Turning tools mostly adopt tungsten carbide material, which is rarely used HSS material, unless for special purposes only!

Tungsten carbide steel is low cost, which applicable range is wider. But in some traditional industries, like automobile/motorcycle industries, pick only one type from P,K, and M type. .. but it is not suitable for optical and optoelectronic industry. Those industries mostly require a high surface roughness (mirror finishing) and the shape accuracy of the tool. Hence the basic knowledge of the diamond tool is very important. The general schools have detailed theory only for HSS high speed steel, tungsten steel tool and cutting tool. But we only know and learn the application and characteristics of diamond toolafter we enter into the community.Not only tungsten carbide or the HSS material, but also you can consider the CBN cutters or diamond tools for non-ferrous metals, the benefits are reducing tool change time and its superior performance and tool life.

Any related questions about various cutting tools and diamond cutter, please feel free to ask us, we would be glad to solve your problem.

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.

 

鎢鋼圓鋸片Part2 – 鎢鋼圓鋸片偏差

繼上一篇【鎢鋼圓鋸片Part1 – 鎢鋼圓鋸片切割】，這一篇為各位介紹鎢鋼圓鋸片中鎢鋼圓鋸片偏差相關要注意的細節!

木材切削用圓鋸片在精準度要不會求太過嚴謹，但要注意，雖圓鋸片在公差規範內，若機台偏差或加工參數不當等因素，仍會造成加工NG，所以造成工件毀損不是單一面向，所以除了要求圓鋸片公差品質外，更要注意可能造成偏差的因素，盡量避免。

鎢鋼圓鋸片偏差小細節要注意：

1. 內孔前磨：內孔需研磨降低表面粗糙度，這樣與機台軸心（無心研磨至鏡面）密和度高，偏差值低。
2. 圓鋸片本身鋼板不夠平整問題：鋼板本身隨著外徑越大其平面研磨時，偏差值就越大，在要求精密切割時，精準度就會受到影響。

鎢鋼圓鋸片JIS規格公差規範:單位（mm）

外徑D		內孔d		刃厚度T1		鋼板厚度T2		參考齒數
規格	容許值	規格	容許值	規格	容許值	規格	容許值
205 255 305 355	±2	25.4 30 60 85	H8	1.8 2.0 2.4 2.8 3.0 3.2 3.5	±0.1	1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.5	±0.08	24,32,40,48, 60,72,80,96, 100,120
405 455 560 610				3.0 3.2 3.5 4.0 4.5 5.0		2.0 2.2 2.5 3.0 3.2 3.5 4.0		32,40,48, 60,72,80 96,100, 120,140

鎢鋼圓鋸片JIS偏擺公差規範:單位（mm）

<td >0.10 <td >0.2<td >0.10 <td >0.2

外徑	外周刃的擺動動容許值（最大）	側邊刀刃的擺動動容許值（最小）
205	0.08	0.15
255	0.08	0.15
305
355
405	0.15	0.25
455	0.15	0.30
510	0.20	0.35
560	0.20	0.35
610	0.20	0.35

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!

 

How to calculate the clamping length of the CNC lathe clamp for cutting tools?

Generally, when working project includes face cutting, outer cutting, and inner cutting three ways and rough or heavy cutting, of course we will try to extend the clamping length, and calculate the suitable pressure.

• Question (1): How to calculate the shortest clamp length without experience?
• Question (2): How to calculate the most proper clamp pressure without experience?

At first we should clarify a concept: When we machine one work piece, the first thing we should think about is “how to cut it into two halves"?

1. The work piece is split in half, we must consider another important issue?
2. How to fold? How long to clamp? Inter clamp or outer clamp? How to set the standard face?

We don’t need to consider above problems if we machine the work pieces of general diameter. But we must consider the wall thickness if we work inner and outer diameters (excessive pressure will cause deformation).

Sum of the above questions:

1. Decided the hold surface
2. The thickness of holding (diameter 2mm. the maximum pressure 1kg/cm square)

For example: the pressure of the gripping surface 15mm long (as large as will not cause any pinch) bore roughing of cut can be unilateral 4mm still will not feed 0.5mm/rev turning length up to 150mm into vibration.

There is no formula for clamping length and pressure, because too many factors to consider (like the work piece shape, cut strength and feed ….)

Suggestions are as following:

thickness unilateral 1mm which pressure is up to 1kg/cm square speed only, 800R.P.M. . the gripping surface should be above 3mm (or more).

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.

 

鎢鋼圓鋸片Part1 – 鎢鋼圓鋸片切割

鎢鋼圓鋸片是木製品加工最常用的刀具，木材是一種有纖維絲地天然資源、木料又分為有直絲與橫絲，目前合板會把直絲與橫絲交互編織做成三合板，刀具接近木料時，直紋木料就不易有毛邊，因為是直紋木料與刀具切割時成直線，所以切割不會有毛邊，但是橫紋木料與切割刀具成90度切割，木料纖維會因刀具偏擺、刀具鈍化、加工參數不正確等相關問題，而出現木料毛邊，其切割會毛邊或粗糙不外乎鋸片本身刃銳利度不夠、變形、齒形對應不當、齒數問題、機台操作參數不當、機台本身精準度…，對應不同加工材質硬度特性及切割要求在鋸片選擇上也是很重要，所以切割木料與切割金屬、塑膠、高硬度材料等材料，在刀具設計就會因客戶需求而做修正處理，當然也包括木材料的不同做調整生產刀具。

鎢鋼圓鋸片包含合金刀頭的種類、基體的材質、直徑、齒數、厚度、齒形、角度、孔徑等多個參數，這些參數決定著鋸片的加工能 力和切削性能。選擇鋸片時要根據鋸切材料的種類、厚度、鋸切的速度、鋸切的方向、送料速度、鋸路寬度需要正確選用鋸片，多瞭解刀具本身及工件、加工機台…，對於加工問題能減少效益自然就提升。

圓鋸片常見齒形：

不同的齒形不同排列組合都是針對加工上有特定作用才設計，簡單舉例，一般常見交叉齒（一左一右排列）其最基本目的是加工時較為平刃省力，切削速度快，修磨相對簡單，；另外其他排列，像切割特定需求的軟材時，交叉齒中間再排入一個三角刃形，其功用能補切割稻中間未切割到的工件…。齒排列上，交叉齒適用鋸切實木、刨花板、中密板應選左右齒，能銳利地將木纖維組織切斷，切口平滑；為了保持槽底平整的開槽，則用平齒齒形或者用左右平組合齒；鋸切貼面板、防火板一般選擇梯平齒…

下一篇將來為各位介紹鎢鋼圓鋸片中鎢鋼圓鋸片偏差相關要注意的細節哦!

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!