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Talking about the Influence of Machine Tool Processing on Slender Rod-like Tools
Slender rod-shaped tools, such as drills and reamers, play a critical role in machining processes. The sharpening of these tools directly determines the shape and precision of their cutting edges, making it a crucial step in ensuring both the performance of the tool and the quality of the final machined part. Proper sharpening not only enhances cutting efficiency but also extends tool life and reduces the risk of defects.
Improving the accuracy of slender rod-shaped tools remains a major challenge in tool manufacturing. This is largely due to the long effective length of the tool, which causes the cutting edge to be far from the clamping area during the process. Since the clamping head typically has a precision of 0.002–0.005 mm, the radial rounding at the cutting edge can reach up to 0.005–0.01 mm (or even more) before grinding begins. This makes achieving high precision extremely difficult.
During the grinding process, especially when working on the sipe or flutes, the grinding force is significant, leading to substantial elastic deformation of the tool. This often results in issues such as asymmetrical grooves, incorrect outer diameter dimensions, blade parameter deviations, and even tool breakage. These problems highlight the importance of careful control throughout the machining process.
First, the machine tool itself plays a key role in determining the accuracy of the tool. The overall precision of the machine directly affects the final result. Additionally, the positioning of the support block is essential for maintaining stability during the machining of slender rods. If the support block is improperly positioned—either too low or too high—it can lead to undesirable shapes, such as inverted or straight cones in the flute area. Therefore, precise adjustment of the support block is vital for achieving the desired accuracy.
Second, the condition and setup of the grinding wheel have a major impact on tool accuracy. Factors such as the wheel’s diameter, angle, flange length, wear, and grain size all influence the outcome. Any error in measuring or inputting the grinding wheel angle can lead to misalignment in the blade width, step surface angles, back angle, or chip flute angles. Ensuring accurate wheel settings is therefore essential for producing high-quality tools.
Third, the cooling effect of the coolant is equally important. A well-performing coolant with appropriate pressure helps to remove heat and chips effectively, reducing surface roughness and improving the overall quality of the tool. Without proper cooling, thermal expansion and poor chip evacuation can lead to inaccuracies and damage to the tool.
In conclusion, the accuracy of slender rod-shaped tools has a direct impact on the quality of the machined parts. Ensuring consistent and reliable precision is crucial to avoid dimensional errors that could lead to serious engineering issues. By addressing the challenges related to machine setup, grinding wheel configuration, and cooling, manufacturers can significantly improve the performance and reliability of these critical cutting tools.