Technology

DHR237 Copper Tungsten multi profile electrode

Material : Copper Tungsten (W70%-Cu30%)

Processing size: 6.5×8(mm) Cutting depth1.5mm (Micro slit shape)
                        6.5×8(mm) Cutting depth1.5mm (Fine prism profile)
                        6.5×8(mm) Cutting depth 3mm (Cylindrical stage profile)

Tool

DHR237(Long Neck Square Type)


●Long neck end mill specialized for machining copper alloy.
●Helix angle 【37.5°】 degrees to achieve both sharpness and finished surface quality that prevents scratches on cutting surface.
●High quality and stable milling performance with long tool life by optimized design and DLC coating.
●Machining copper tungsten electrodes is also effective.


Cutting Conditions & Measuring result

Micro slit shape

【Cutting condition】

Process Roughing(Slotting) Finishing(Side milling)
Tool DHR237 Φ0.3×1 DHR237 Φ0.3×2
Spindle speed
(min-1)
25,000
Feed
(mm/min)
200
100※
150
Depth of cut
ap×ae(mm)
ap 0.01
ap 0.005※
0.1×0.005
Stock
(mm)
0.005 -
Coolant Water-insoluble fluid
Cutting time 42min 12min

※Guide part machining from the upper surface to -0.05mm.

Result

Side

Surface roughness Ra0.101µm


Slot width

Target 0.310mm
Actual 0.307mm
Deflection Within 0.001mm


【Points of machining】

To make the deflection amount minimize at slit profile as much as possible, we applied the following method:

1.In order to make a "guide" to prevent the tool from deflection, the feed rate and depth of cut are reduced up to a position of -0.05 mm from the top surface of the slit.

2.The area below the “guide” is machined with normal cutting conditions.

3.The effect of making the guide suppresses tool deflection, and was able to machine highly accurate slit profile with little deflection error.


Fine prism profile

【Cutting condition】

Process Roughing Finishing
Slotting Side milling
Tool DHR237 Φ0.5×1.5
Spingle speed
(min-1)
26,000
Feed
(mm/min)
500 550
Depth of cut
ap×ae(mm)
ap0.07 0.3×0.02 0.3×0.005
Stock
(mm)
0.05 0.005 -
Coolant Water-insoluble fluid
Cutting time 13min


【Measuring result】

Side

Surface roughness Ra 0.197 µm




Slot width   
AB
Target 0.600mm 0.600mm
Actual 0.601mm 0.599mm

Deflection Within 0.001mm


Cylindrical stage profile

【Cutting condition】

Process Roughing Finishing
Φ1.8 Helical milling Side milling
Tool DHR237 Φ0.8×3
Spindle speed
(min-1)
12,000
Feed
(mm/min)
500
Depth of cut
ap×ae(mm)
ap0.02
(Helical R=0.25)
0.5×0.02 0.5×0.005
Stock
(mm)
0.25 0.005 -
Coolant Water-insoluble fluid
Cutting time 33min


【Measuring result】

   

Surface roughness

α β
Ra 0.182 µm Ra 0.176 µm


Center hole diameter

Target 1.800mm
Actual 1.797mm

Related Movie

Long neck end mill for copper electrode (DHR237)