Bearbeitung von 2D-Flächen
In diese Kategorie fallen einerseits direkt an der Maschine ausgeführte Bearbeitungsprozesse wie Planfräsen, Fräsen von Taschen und geraden Wänden. Andererseits auch Operationen für komplexe Geometrien, die mithilfe einer CAM-Software programmiert werden.
Werkzeugübersicht für folgende Bearbeitungsschritte:
Schruppen
Die Schruppoperation ist für den Großteil des Zerspanungsvolumens verantwortlich. Spezielle Frässtrategien wie die Hochvorschubbearbeitung oder das trochoide Fräsen können die Bearbeitungszeit reduzieren und somit die Wirtschaftlichkeit steigern. Neben Werkzeugen mit Wendeschneidplatten und Vollhartmetallfräsern kommen Hochleistungsfräser mit spezieller Schruppgeometrie zum Einsatz.
Residual material roughing
After roughing, in a second machining step, users machine the residual material, especially in corners and cavities, removing material as constantly as possible. Usually tools with corner radius or high-feed milling cutters are used. In some cases a ball cutter can be used to remove the residual material in corners.
Pre-finishing
If there are high demands on dimensional accuracy and surface finish, semi-finishing is recommended before finishing. With pre-finishing, machining approaches the final mould profile. The aim is to obtain a residual material that is as constant as possible in order to enable fast finishing with high demands on the surface quality. The stock removal after roughing is approx. 0.5-1 mm for hardened materials and 0.03-0.5 mm for soft materials. After pre-finishing, the constant stock removal is 0.05-0.1 mm for hardened materials or 0.1-0.3 mm for soft materials.
Finishing
The finishing process removes the remaining material in order to achieve the final shape. After pre-finishing, stock removal is 0.05-0.1 mm for hardened materials or 0.1-0.3 mm for soft materials. Ball and/or corner radius milling cutters are the tools of choice, regardless of the final contours of the workpiece.
Residual material finishing
The increasingly complex properties of the shapes to be produced require milling of the residual material after finishing, mainly in the corners. Solid carbide ball cutters are usually used for this.