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1、Why are we doing this?Cost distribution for manufacturing of a die casting toolMachining 65%Assembly & Adjustment 10%Heat treatment 5%Work material 20%Some factors which influence the final resultMaterialMaterialCutting toolCutting toolCutting dataCutting dataMould designMould designCAMCAMMachine eq
2、uipmentMachine equipmentResultResultFactors that chiefly influence the machinabilityChemical compositionMicrostructureHardnessNon-metallic inclusionsResidual stressesSulphideshardness(Kp/mm2)melting point (C) -MnS1701600Sulphideshardness(Kp/mm2)melting point (C) -MnS1701600Oxideshardness(Kp/mm2)melt
3、ing point (C)- Al2O330002050- SiO21600172012001400Oxideshardness(Kp/mm2)melting point (C)- Al2O330002050- SiO21600172012001400- 2CaO Al2O3SiO2Non metallic inclusions - hardness and melting point020406080100120140160180200220240260280300320340100Machinability v30m/min120 140 160 180 200 220 240 260 2
4、80 300 320 340 360 380 400 420 440Material with low carbide contentMaterial with low carbide contentMaterial with high carbide contentMaterial with high carbide contentHardness HBVANADIS 23VANADIS 10VANADIS 4ELMAXSVERKER 21SVERKER 3VANADIS 60VANADIS 30VANADIS 6WEARTECROLTECMaterial with high carbide
5、 content (Spray formed)Material with high carbide content (Spray formed)Machinability as a function of hardness and carbide content in the work materialIMPAX SupremeIMPAX HI HARDORVARRAMAX 2STAVAX ESRCarbide structureIngot cast tool steel PM produced tool steelSpray formed tool steelM23C7 1700 HVMC,
6、 M2C 2800 HVMC, M2C 2800 HVHardness of coatingsHigh performance steelsRequirements Requirements of Influence on the from end usermaterial propertiesmachinability Impact strength/High purityPoor chip breaking polishabilityand stickingWear resistanceHigh carbide contentHigh tool wear Avoid heat treatm
7、entHigh delivery hardness Longer machining timeCorrosion resistanceHigh alloying contentPoor chip breaking and stickingAdhesive wear Abrasive wear High hardnessDetermination of the machinability of a materialFour crucial machining factorsSurface finishChip formationTool wearCutting forces-150-100-50
8、05010015020025030035000,020,040,060,080,10,12Time (s)Fx Fy Fz0102030405065 6070HSSCoated HSSCarbideCeramicCBNCutting tool material10030HB 40070Hardness of workpiece HRC405060300200Cutting tool material for different tool steel hardness? ?P P? ?MM? ?K KThe ISO classificationP-area: Long chipping mate
9、rials Steel, cast steel, stainless steeland malleable ironQRO 90, ORVAR, ARNE, IMPAX, RAMAX-2, STAVAX ESR, CALMAX, HOTVAR Long chipping materials Steel, cast steel, stainless steeland malleable ironQRO 90, ORVAR, ARNE, IMPAX, RAMAX-2, STAVAX ESR, CALMAX, HOTVARK-area: Short chipping materials Cast i
10、ron, hardened steel, aluminiumbronze and plastics, etc.All PM and sprayformed steels, SVERKER, SLEIPNER, RIGOR Short chipping materials Cast iron, hardened steel, aluminiumbronze and plastics, etc.All PM and sprayformed steels, SVERKER, SLEIPNER, RIGORM-area: Stainless steels, Titanium alloys DIEVAR, CORRAX, STAVAX SUPREME, ARNE, CALMAX Stainless steels, Titanium alloys DIEVAR, CORRAX, STAVAX SUPREME, ARNE, CALMAXCoromant Milling Grade Recommendation in Uddeholm Tool SteelsSuitable grades for roughing operations, abrasive wear
