Ten key points to use slotting tools!

1.
Understanding groove types
It is important to understand the three main types of grooves: outer circular grooves, inner hole grooves, and end face grooves. The outer groove is the easiest to machine because gravity and coolant can help with chip removal. In addition, the machining of outer grooves is visible to the operator and can be directly and relatively easily checked for machining quality. But it is also necessary to avoid some potential obstacles in workpiece design or clamping. Generally speaking, the cutting effect is best when the tip of the slotting tool is kept slightly below the centerline.
The inner hole groove cutting is similar to the outer diameter groove cutting, but the difference is that the application of coolant and chip removal are more challenging. For inner hole groove cutting, the best performance can be achieved when the tool tip position is slightly higher than the centerline. When processing end face grooves, the tool must be able to move in the axial direction, and the radius of the tool's back face must match the radius being processed. The machining effect is best when the tip position of the end face groove cutting tool is slightly higher than the centerline.
2.
Processing Machine Tools and Applications
In groove cutting, the design type and technical conditions of the machine tool are also basic elements that need to be considered. Some of the main performance requirements for machine tools include: having sufficient power to ensure that the tool operates within the correct speed range without stalling or shaking; Has sufficient rigidity to complete the required cutting process without vibration; Having a sufficiently high coolant pressure and flow rate to assist in chip removal; Has sufficient accuracy. In addition, it is crucial to properly adjust and calibrate the machine tool in order to process the correct groove shape and size.
3.

Understand the material characteristics of the workpiece
Familiarity with some characteristics of workpiece materials, such as tensile strength, work hardening characteristics, and toughness, is crucial for understanding the impact of workpieces on cutting tools. When processing different workpiece materials, it is necessary to use different combinations of cutting speed, feed rate, and tool characteristics. Different workpiece materials may also require specific tool geometries to control chips, or use specific coatings to extend tool life.
4.
Correct selection of cutting tools
The correct selection and use of cutting tools will determine the cost-effectiveness of processing. The groove cutting tool can process the geometric shape of the workpiece in two ways: first, the entire groove can be machined with one cut; The second is to rough machine the final size of the groove through multiple cuts and steps. After selecting the geometric shape of the tool, it is possible to consider using a tool coating that can improve chip removal performance.
5.
Forming tools
When processing in large quantities, the use of forming tools should be considered. Forming tools can create all or most of the groove shapes through a single cut, which can empty the tool position and shorten the processing cycle time. One disadvantage of non blade forming tools is that if one tooth breaks or wears out faster than the other teeth, the entire tool must be replaced. Another important factor to consider is the control of the chips generated by the cutting tool and the machine power required for forming cutting.
6.
Select a single point multifunctional tool
The use of multifunctional tools can generate tool paths in both axial and radial directions. In this way, the tool can not only process grooves, but also turn diameters, interpolate radii, and process angles. The tool can also perform multi-directional turning. Once the blade enters the cutting process, it moves axially from one end of the workpiece to the other while maintaining contact with the workpiece at all times. The use of multifunctional cutting tools can allocate more time to cutting workpieces, rather than for tool changing or empty stroke movement. Multi functional cutting tools also help reduce the machining process of the entire workpiece.
7.
Adopting the correct processing sequence
Reasonable planning of the optimal machining sequence requires consideration of multiple factors, such as the variation of workpiece strength before and after groove machining, as the strength of the workpiece will decrease after machining the groove first. This may prompt the operator to use feed rates and cutting speeds below the optimal value in the next process to reduce chatter, while reducing cutting parameters may lead to longer processing time, shorter tool life, and unstable cutting performance. Another factor to consider is whether the next process will push burrs into the already processed grooves. As an empirical rule, it can be considered to start machining from the point farthest from the tool holder after completing the outer and inner diameter turning, and then machining grooves and other structural features.
8.
Adopting the correct processing sequence
The feed rate and cutting speed play a crucial role in groove machining. Incorrect feed rates and cutting speeds may cause chatter, reduce tool life, and prolong machining cycle time. The factors that affect feed rate and cutting speed include workpiece material, tool geometry, type and concentration of coolant, blade coating, and machine performance. In order to correct problems caused by unreasonable feed rate and cutting speed, secondary machining is often required. For various types of tools, although many sources of information on "optimized" feed rates and cutting speeds can be listed, the latest and most practical information usually comes from tool manufacturers.
9.
Choose blade coating
Coating can significantly improve the lifespan of hard alloy blades. Due to the fact that coatings can provide a lubricating layer between cutting tools and chips, they can also shorten processing time and improve the surface smoothness of workpieces. The commonly used coatings currently include TiAlN, TiN, TiCN, etc. In order to achieve optimal performance, the coating must match with the material being processed.
10.
cutting fluid
The correct application of cutting fluid means providing sufficient cutting fluid for the cutting points where the grooved blade comes into contact with the workpiece. Cutting fluid plays a dual role in cooling the cutting area and assisting in chip removal. When machining blind hole inner diameter grooves, increasing the cutting fluid pressure at the cutting point is very effective for improving chip removal. For groove machining of some difficult to machine materials (such as high toughness and high viscosity materials), high-pressure cooling has obvious advantages.
The concentration of water-soluble oil-based coolant is also crucial for groove machining of difficult to machine materials. Although the typical coolant concentration range is 3% -5%, in order to improve the lubricity of the coolant and provide a protective layer for the cutting edge, the effect of increasing the coolant concentration (up to 30%) can also be tested.