Ten Common Problems in Deep Hole Machining and Their Solutions
In the process of deep hole processing, often appear in the workpiece size accuracy, surface quality and tool life and other issues, how to reduce or even avoid these problems, is our urgent problem to be solved, the following summary of the deep hole processing in the common 10 kinds of problems and solutions.
1. The aperture increases and the error is large
1) cause
Reamer outer diameter design value is too large or hinge cutting edge of the burr; cutting speed is too high; improper feed or processing margin is too large; reamer main angle is too large; reamer bending; hinge cutting edge stick The cutting fluid selection is not appropriate; installation reamer when the taper shank surface oil is not wiped clean or tapered bumps; taper shank flat tail offset loading Machine spindle spindle taper shank cone interference; spindle bending or spindle bearing too loose or damaged; Reamer floating is not flexible; and the workpiece is different from the shaft and the reed hole when the hands are not uniform force, so that reamer left and right shaking.
2) to resolve measures
According to the specific circumstances appropriate to reduce the reamer diameter; reduce the cutting speed; appropriate to adjust the feed or reduce the processing margin; appropriate to reduce the main declination; straighten or scrapped bending can not use the reamer; Qualified to control the swing within the allowable range; choose better cooling performance of the cutting fluid; installation reamer must be reamer taper shank and machine tool spindle cone internal oil wipe clean, tapered surface with leaking stone repair; To adjust or replace the spindle bearings; re-adjust the floating chuck, and adjust the coaxial; pay attention to the correct operation.
2. Reduced aperture
1) cause
Reamer outer diameter design value is too small; cutting speed is too low; feed too large; reamer main angle is too small; cutting fluid selection is not appropriate; sharpening part of the reamer wear, Shrinkage; hinge steel, the margin is too large or reamer is not sharp, easy to produce elastic recovery, so that the aperture is reduced and the hole is not round, aperture failure.
2) to resolve measures
Replace the reamer diameter; appropriate to improve the cutting speed; appropriate to reduce the feed; appropriate increase in the main declination; select the lubrication performance of good oily cutting fluid; regular exchange reamer, the correct sharpening reamer cutting part; Knife size, should consider the above factors, or according to the actual situation value; for experimental cutting, take the appropriate margin, the reamer grinding sharp.
3. The hinged hole is not round
1) cause
The reamer is too long, the rigidity is insufficient, the vibration occurs when the reamer is too small; the hinge cutting edge is narrow; the reaming allowance is partial; the hole surface has the notch, the cross hole; the hole surface has the trachoma, Spindle bearing loose, no guide sleeve, or reamer and guide sleeve with the gap is too large and due to thin-walled workpiece clamping too tight, remove the workpiece after the deformation.
2) to resolve measures
Rigid under the reamer can be used in different reamer reamer, reamer installation should be rigid connection, increase the main declination; use qualified reamer, control the pre-processing hole position tolerance; Reamer, the use of longer, more precise guide sleeve; selection of qualified blanks; reamer reamer with more precision hole, the machine should adjust the spindle clearance, guide sleeve with the gap should be higher or appropriate Of the clamping method, reducing the clamping force.
4. The inner surface of the hole has a clear edge
1) cause
The reamer margin is too large; reamer cutting part of the rear angle is too large; hinge cutting edge with too wide; workpiece surface with pores, trachoma and spindle swing is too large.
2) to resolve measures
Reduce the reaming allowance; reduce the cutting part of the rear angle; grinding blade width; select qualified blank; adjust the machine tool spindle.
5. The hole surface roughness value is high
1) cause
Cutting speed is too high; cutting fluid selection is not appropriate; reamer main angle is too large, hinge cutting edge is not the same circumference; reaming allowance is too large; reaming allowance is not uniform or too small, ; Reamer cutting part of the poor tolerance, the edge is not sharp, the surface rough; hinge cutting edge with too wide; reaming when the chip is poor; reamer excessive wear; reamer bumps, edge burr or collapse Edge; edge of the chip; because of the material relationship, does not apply to zero angle or negative front angle reamer.
2) to resolve measures
Reduce the cutting speed; according to the processing material to select the cutting fluid; appropriate to reduce the main deflection angle, the correct sharpening hinge cutting edge; appropriate to reduce the reaming allowance; to improve the reaming hole position accuracy and quality or increase the reaming allowance ; Use qualified reamer; grinding blade width; according to the specific circumstances to reduce the number of reamer teeth, to increase the chip flute space or with a blade angle of the reamer, so that chip removal; regular replacement reamer, Cut the area to wear; reamer in the grinding, use and transport process, should take protective measures to avoid bruises; on the wounded reamer, the application of special thin stone will be wound reamer repair, or replace the hinge Knife; with oil stone trim to qualified, with an angle of 5 ° -10 ° reamer.
6. Reamer has a low service life
1) cause
Reamer material is not appropriate; reamer in the grinding when the burn; cutting fluid selection is not appropriate, the cutting fluid failed to flow smoothly, cutting and hinge cutting edge grinding surface roughness value is too high.
2) to resolve measures
According to the processing material selection reamer material, can be used carbide reamer or coated reamer; strictly control the amount of sharpening cutting, to avoid burns; often based on the correct selection of cutting fluid processing materials; often remove the chips inside the chip, with enough Pressure of the cutting fluid, after grinding or grinding to meet the requirements.
7. The position of the hinged hole is extremely poor
1) cause
Guide sleeve wear; guide sleeve at the end of the workpiece too far; guide sleeve length is short, poor precision and spindle bearing loose.
2) to resolve measures
Regularly change the guide sleeve; extended guide sleeve, to improve the guide sleeve and reamer clearance with the accuracy; timely maintenance of machine tools, adjust the spindle bearing clearance.
8. Reamer knife teeth
1) cause
The reamer margin is too large; the workpiece material hardness is too high; cutting edge swing is too large, the cutting load is not uniform; reamer main angle is too small, so that the cutting width increases; hinge hole or blind hole, too much chips , And not timely removal and sharpening when the knife has been ground.
2) to resolve measures
Modify the size of the pre-processing aperture; reduce the hardness of the material or switch to the negative front angle reamer or carbide reamer; control swing in the qualified range; increase the main declination; pay attention to the timely removal of chips or with a blade angle reamer ; Pay attention to the quality of grinding.
9. Reamer handle broken
1) cause
Reaming hole margin is too large; hinge cone hole, coarse fine hinge balance distribution and cutting the amount of choice is not appropriate; reamer knife bitter space is small, chip jam.
2) to resolve measures
Modify the size of the pre-processing aperture; modify the balance distribution, a reasonable choice of cutting the amount; reduce the number of reamer teeth, increase the bitter space or tooth gap to wear a tooth.
10. The center line of the reaming hole is not straight
1) cause
Reaming before drilling deflection, especially when the aperture is small, because the reamer rigidity is poor, can not correct the original curvature; reamer main declination is too large; poor orientation, so that reamer in the hinge easy to deviate Direction; cutting part of the inverted cone is too large; reamer in the middle of the intermittent hole clearance; hand reaming, forced in one direction too large, forcing the reamer to one end of the deflection, breaking the vertical reaming.
2) to resolve measures
Increase the reaming or boring process correction hole; reduce the main declination; adjust the appropriate reamer; swap with a guide part or extended cutting part of the reamer; pay attention to the correct operation.
In the process of deep hole processing, often appear in the workpiece size accuracy, surface quality and tool life and other issues, how to reduce or even avoid these problems, is our urgent problem to be solved, the following summary of the deep hole processing in the common 10 kinds of problems and solutions.
1. The aperture increases and the error is large
1) cause
Reamer outer diameter design value is too large or hinge cutting edge of the burr; cutting speed is too high; improper feed or processing margin is too large; reamer main angle is too large; reamer bending; hinge cutting edge stick The cutting fluid selection is not appropriate; installation reamer when the taper shank surface oil is not wiped clean or tapered bumps; taper shank flat tail offset loading Machine spindle spindle taper shank cone interference; spindle bending or spindle bearing too loose or damaged; Reamer floating is not flexible; and the workpiece is different from the shaft and the reed hole when the hands are not uniform force, so that reamer left and right shaking.
2) to resolve measures
According to the specific circumstances appropriate to reduce the reamer diameter; reduce the cutting speed; appropriate to adjust the feed or reduce the processing margin; appropriate to reduce the main declination; straighten or scrapped bending can not use the reamer; Qualified to control the swing within the allowable range; choose better cooling performance of the cutting fluid; installation reamer must be reamer taper shank and machine tool spindle cone internal oil wipe clean, tapered surface with leaking stone repair; To adjust or replace the spindle bearings; re-adjust the floating chuck, and adjust the coaxial; pay attention to the correct operation.
2. Reduced aperture
1) cause
Reamer outer diameter design value is too small; cutting speed is too low; feed too large; reamer main angle is too small; cutting fluid selection is not appropriate; sharpening part of the reamer wear, Shrinkage; hinge steel, the margin is too large or reamer is not sharp, easy to produce elastic recovery, so that the aperture is reduced and the hole is not round, aperture failure.
2) to resolve measures
Replace the reamer diameter; appropriate to improve the cutting speed; appropriate to reduce the feed; appropriate increase in the main declination; select the lubrication performance of good oily cutting fluid; regular exchange reamer, the correct sharpening reamer cutting part; Knife size, should consider the above factors, or according to the actual situation value; for experimental cutting, take the appropriate margin, the reamer grinding sharp.
3. The hinged hole is not round
1) cause
The reamer is too long, the rigidity is insufficient, the vibration occurs when the reamer is too small; the hinge cutting edge is narrow; the reaming allowance is partial; the hole surface has the notch, the cross hole; the hole surface has the trachoma, Spindle bearing loose, no guide sleeve, or reamer and guide sleeve with the gap is too large and due to thin-walled workpiece clamping too tight, remove the workpiece after the deformation.
2) to resolve measures
Rigid under the reamer can be used in different reamer reamer, reamer installation should be rigid connection, increase the main declination; use qualified reamer, control the pre-processing hole position tolerance; Reamer, the use of longer, more precise guide sleeve; selection of qualified blanks; reamer reamer with more precision hole, the machine should adjust the spindle clearance, guide sleeve with the gap should be higher or appropriate Of the clamping method, reducing the clamping force.
4. The inner surface of the hole has a clear edge
1) cause
The reamer margin is too large; reamer cutting part of the rear angle is too large; hinge cutting edge with too wide; workpiece surface with pores, trachoma and spindle swing is too large.
2) to resolve measures
Reduce the reaming allowance; reduce the cutting part of the rear angle; grinding blade width; select qualified blank; adjust the machine tool spindle.
5. The hole surface roughness value is high
1) cause
Cutting speed is too high; cutting fluid selection is not appropriate; reamer main angle is too large, hinge cutting edge is not the same circumference; reaming allowance is too large; reaming allowance is not uniform or too small, ; Reamer cutting part of the poor tolerance, the edge is not sharp, the surface rough; hinge cutting edge with too wide; reaming when the chip is poor; reamer excessive wear; reamer bumps, edge burr or collapse Edge; edge of the chip; because of the material relationship, does not apply to zero angle or negative front angle reamer.
2) to resolve measures
Reduce the cutting speed; according to the processing material to select the cutting fluid; appropriate to reduce the main deflection angle, the correct sharpening hinge cutting edge; appropriate to reduce the reaming allowance; to improve the reaming hole position accuracy and quality or increase the reaming allowance ; Use qualified reamer; grinding blade width; according to the specific circumstances to reduce the number of reamer teeth, to increase the chip flute space or with a blade angle of the reamer, so that chip removal; regular replacement reamer, Cut the area to wear; reamer in the grinding, use and transport process, should take protective measures to avoid bruises; on the wounded reamer, the application of special thin stone will be wound reamer repair, or replace the hinge Knife; with oil stone trim to qualified, with an angle of 5 ° -10 ° reamer.
6. Reamer has a low service life
1) cause
Reamer material is not appropriate; reamer in the grinding when the burn; cutting fluid selection is not appropriate, the cutting fluid failed to flow smoothly, cutting and hinge cutting edge grinding surface roughness value is too high.
2) to resolve measures
According to the processing material selection reamer material, can be used carbide reamer or coated reamer; strictly control the amount of sharpening cutting, to avoid burns; often based on the correct selection of cutting fluid processing materials; often remove the chips inside the chip, with enough Pressure of the cutting fluid, after grinding or grinding to meet the requirements.
7. The position of the hinged hole is extremely poor
1) cause
Guide sleeve wear; guide sleeve at the end of the workpiece too far; guide sleeve length is short, poor precision and spindle bearing loose.
2) to resolve measures
Regularly change the guide sleeve; extended guide sleeve, to improve the guide sleeve and reamer clearance with the accuracy; timely maintenance of machine tools, adjust the spindle bearing clearance.
8. Reamer knife teeth
1) cause
The reamer margin is too large; the workpiece material hardness is too high; cutting edge swing is too large, the cutting load is not uniform; reamer main angle is too small, so that the cutting width increases; hinge hole or blind hole, too much chips , And not timely removal and sharpening when the knife has been ground.
2) to resolve measures
Modify the size of the pre-processing aperture; reduce the hardness of the material or switch to the negative front angle reamer or carbide reamer; control swing in the qualified range; increase the main declination; pay attention to the timely removal of chips or with a blade angle reamer ; Pay attention to the quality of grinding.
9. Reamer handle broken
1) cause
Reaming hole margin is too large; hinge cone hole, coarse fine hinge balance distribution and cutting the amount of choice is not appropriate; reamer knife bitter space is small, chip jam.
2) to resolve measures
Modify the size of the pre-processing aperture; modify the balance distribution, a reasonable choice of cutting the amount; reduce the number of reamer teeth, increase the bitter space or tooth gap to wear a tooth.
10. The center line of the reaming hole is not straight
1) cause
Reaming before drilling deflection, especially when the aperture is small, because the reamer rigidity is poor, can not correct the original curvature; reamer main declination is too large; poor orientation, so that reamer in the hinge easy to deviate Direction; cutting part of the inverted cone is too large; reamer in the middle of the intermittent hole clearance; hand reaming, forced in one direction too large, forcing the reamer to one end of the deflection, breaking the vertical reaming.
2) to resolve measures
Increase the reaming or boring process correction hole; reduce the main declination; adjust the appropriate reamer; swap with a guide part or extended cutting part of the reamer; pay attention to the correct operation.
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