Optimize chip control with high pressure coolant

In metal cutting, the cutting fluid has a dual role: to lubricate and wash the chips. Whether machining requires the use of oil-based cutting fluids or water-based cutting fluids, its function in machining is to form a hydraulic layer between the cutting edge and the workpiece (which helps to transfer cutting heat from the tip to the chip). The heated chips are then accelerated from the cutting zone.

The coolant is usually used by pouring the coolant directly into the cutting zone using a pipe mounted outside the tool. In today's manufacturing environment, many processing plants are re-evaluating how coolant is used in machining, especially turning.

Turning (and drilling) is a continuous cutting process that requires the cutting edge to remain in contact with the workpiece throughout the cutting process. In the age dominated by high speed steel tools, since the feed rate and cutting speed are relatively low, it is sufficient as long as the poured coolant can lower the temperature enough to keep the cutting edge of the tool intact. However, with the advancement of machine tool technology and the use of cemented carbide tools, the processing parameters have been greatly improved. If the cutting fluid is still cast in the cutting zone with a temperature of up to 1000 °C in the conventional way, the cutting fluid will immediately evaporate. This creates a high pressure steam zone that effectively blocks the flow of low pressure coolant from reaching the cutting edge. In order to solve this problem, high pressure coolant systems have been developed for modern machine tools.

However, high pressure coolant can only solve part of the problem. In order to benefit from a high pressure coolant system, the coolant must be properly transported to the location where it is most needed for processing. To this end, Sandvik Coromant has introduced a cutting shank that maximizes the processing potential of high-pressure coolants, which can increase cutting productivity and extend tool life by 50%.

This new tool holder is called CoroTurn HP (HP is "high pressure") and it is used with the Capto modular quick change tool system. The new system can be used on any machine tool with high pressure coolant supply and Capto coupling system (including multi-tasking machines, CNC vertical lathes, turning centers, etc.).

There are 2~3 cutting fluid nozzles on this tool holder. The position and injection direction depend on the type of tool used and the processing requirements. These nozzles are positioned close to the tool/workpiece interface, using a high pressure cutting fluid with a pressure of 1000 psi, which actually has the added function of controlling chips.

During processing, HP toolholders use high-pressure (1000 psi) cutting fluid from 2 to 3 precision directional small nozzles to penetrate the heat affected zone formed by machining to achieve faster and more efficient cooling of the cutting insert and optimization The purpose of chip control. The nozzle forms a wedge between the upper surface of the cutting insert and the lower surface of the chip that is cut from the workpiece to help control chip formation, reduce blade wear, and break the chips into smaller pieces. Conducive to faster discharge from the cutting zone.

Although the importance of chip control is much lower in roughing than in finishing, the precise use of cutting fluid with HP shanks reduces the cutting temperature and allows for higher cutting speeds or longer tool life. On the Other hand, in the finishing process, since the amount of depth of cut and the amount of feed are small, the chip control problem is more likely to occur. In addition, the use of HP shanks to eliminate the formation of “nest nest” swarf is an important advantage as more and more processing plants use unattended or low-cost automated processing.

In summary, by applying high-pressure coolant properly, it is possible to fully release higher cutting speeds, longer tool life, less machining interruptions, better predictability and greater potential for safer automated machining.

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