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When programming, a programmer must determine the appropriate cutting parameters for each machining process. Selecting these parameters requires careful consideration of various factors that influence the cutting process. It's essential to choose the right cutting conditions and set reasonable values to enhance both the quality and efficiency of the machining operation. Several factors affect the cutting conditions, including:
- The rigidity of the machine tool, cutting tools, and workpiece
- Cutting speed, depth of cut, and feed rate
- Workpiece accuracy and surface finish requirements
- Tool life and maximum productivity
- Type of cutting fluid and cooling method used
- Hardness of the workpiece material and its heat treatment status
- Number of parts to be machined
- Machine tool lifespan
Among these, cutting speed, depth of cut, and feed rate are the most critical elements. The cutting speed directly impacts the overall efficiency of the process. If it's too low, the machining time increases, and the tool may not perform optimally. On the other hand, if the speed is too high, although the time is reduced, excessive heat can build up, potentially reducing the tool’s lifespan. There are several factors that determine the appropriate cutting speed, which include:
1. **Tool Material**: Different materials have varying maximum allowable cutting speeds. For example, high-speed steel tools typically operate below 50 m/min, while carbide tools can handle up to 100 m/min, and ceramic tools can go as high as 1000 m/min.
2. **Workpiece Material**: The hardness of the material being machined affects the cutting speed. Softer materials allow for higher speeds, while harder ones require slower speeds to avoid tool damage.
3. **Tool Life Expectancy**: A longer tool life means using a lower cutting speed. Conversely, if a faster process is needed, the speed can be increased at the cost of shorter tool life.
4. **Depth of Cut and Feed Rate**: Larger depths of cut and higher feed rates increase cutting resistance and heat generation, so the cutting speed should be adjusted accordingly.
5. **Tool Geometry**: The shape, angle, and sharpness of the cutting edge all play a role in determining the optimal cutting speed.
6. **Coolant Use**: The presence of coolant and the machine’s rigidity can allow for higher cutting speeds, while poor cooling or machine instability may require a reduction in speed.
Of all these factors, the material of the tool has the most significant impact on cutting speed.
The depth of cut is primarily limited by the rigidity of the machine tool. If the machine is rigid enough, the depth should be maximized to reduce the number of passes. If machining accuracy isn't a concern, the depth can match the material's initial allowance.
Spindle speed is calculated based on the tool's and machine's allowable cutting speed. This can be determined through calculation or by referring to standard tables.
Feed rate (in mm/rev or mm/min) is chosen depending on the required accuracy, surface finish, and the properties of the tool and workpiece. The maximum feed rate is also constrained by the machine’s stiffness and the capabilities of the feed system and CNC control.
When selecting cutting parameters, the programmer must ensure the chosen values align with the machine’s specifications and the tool’s durability. Analogical methods can also be used for reference. Regardless of the approach, it's crucial to ensure the tool lasts long enough to complete one part or at least half a shift, to maintain efficient and consistent production.