Just as precision tools are used to personalize the workpiece, the choice of the appropriate holder is unique. Extensive experiments with 8mm solid carbide end mills show the advantages and disadvantages of the most popular tool holders.

Fritz Weg worked with the Dillenburg Vocational School and the Giessenfriedberg Specialist University to conduct detailed monitoring and auditing of six tool holders. Some unexpected conclusions were obtained in various test and milling tests. To this end, these conclusions were analyzed from the technical and economic perspective of tool/mold manufacturing. The following tool holder systems were studied in accordance with DIN 69871 SK40:

·Standard type clamp chuck;
·High-precision clamp chuck;
· Powergrip chuck chuck;
·Hydraulic expansion chuck;
·Polygon chuck;
· Shrink the chuck.

Various tests were performed on a Bridgeport VMC 600/22/TNC426P vertical machining center. Two 8 mm diameter four-blade solid carbide milling cutters and cylindrical shank with ISO tolerance class h5 were used:

LMT-Fette's 63mm long DHC Inox 1525C end mill with a blade length of 19mm and a twist angle of 41;

Seco-Jabro's 91L080 end mill, 100mm long, with a blade length of 40mm and a twist angle of 30°.

Recommendations for use in mold and molding manufacturing

The milling test was carried out using two materials from each batch. One material is C45 W/U (1.1730) and the other is 40CrMnMoS8-6 (1.2312). Based on the results of weighted analysis of bending strength, ultimate depth of cut, concentricity, holding torque, geometrical tolerances and surface quality, the following recommendations can be made for the optimum application range of the shank in mold and forming. .

The standard clamp chuck is a universal chuck for easy and medium-duty cutting operations with medium quality requirements. When using solid carbide tools, the relatively high 10μm eccentricity has a large impact on tool life and edge cracking (Figure 1).


Figure 1 Relationship between tool shank deflection and radial force

Precision clamp chucks provide excellent protection of the tool and mandrel support components with their good concentricity. The 8mm diameter clamp has a high radial stiffness and a clamping torque of more than 70 N·m, thus allowing the tool to achieve a large external probe amplitude and a large diameter. This is a lower cost general purpose chuck. In the mold manufacturing, since the contour of the reinforced chuck body is relatively complicated, it is necessary to pay attention to the contour interference problem.

The Powergrip's powerful clamping system has the advantage of its high clamping force, which, thanks to its anti-vibration damping characteristics, allows for a large depth of cut (Fig. 2). Especially when the tool has a large external probe, the clamping system can achieve good manufacturing quality. This type of system (clamping unit is about 6,700 euros) is relatively expensive, especially for the necessary peripherals; however, if the difficulty of cutting operations is medium and above, and the manufacturing quality is high during the roughing stage, then This kind of investment is also worthwhile. Its usability within the scope of finishing can be judged on a case-by-case basis.


Figure 2 Maintaining torque when the clamping diameter is 6mm

By using the tensioning method of the hydraulic medium, the hydraulic expansion chuck will only flutter when it encounters a large clamping section. However, from the perspective of geometrical tolerances, the influence of large interaction forces should be avoided. The strength of the hydraulic expansion chuck is that it achieves good quality at low depth of cut and finishing (Figure 3).


Figure 3 Relationship between roughness Rz and milling

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