Burr Suppression Technology In Precision Milling Of Mould Copper Electrode

With the rapid development of personal electronic products,people pay more and more attention to their appearance and quality.This puts forward higher requirements for micro precision mould.Therefore,the copper electrode of the precision mould needs to have high accuracy and surface quality.The burr size of each edge of the electrode should be suppressed within 5 microns.As a typical plastic material,copper is really easy to produce burr during machining.The burrs of the copper electrode will directly affect the quality of the mould,and then affect the quality of the processed products.Under these circumstance,the appearance of the product is bad or even defective.Due to the small size and complex characteristics of the copper electrode of the precision mould,these burrs are difficult to be removed through the additional process without damaging the electrode under the existing technology.The problem that burrs are easy to occur in the milling of copper electrode of precision mould is studied.The characteristics of copper electrode and the types of burr produced are analyzed.The formation process of burr and the relationship between burr size and tool parameters are analyzed by simulation.A left-hand round-angle burr-suppress milling cutter is designed.The burr suppression machining process for copper electrode of precision mould is proposed.The validity of the left-hand round-angle burr-suppress milling cutter and the burr suppression machining process is verified by the design test.The details are as follows:(1)Analysis of burr formation mechanism in copper electrode milling.The typical characteristics and the types of burrs that are easy to generate of copper electrode of precision mould are analyzed.By using ABAQUS finite element simulation software,a 3D cutting simulation model is established.The formation process of side direction burr is studied.The approximate characterization method of side direction burr size is proposed.By using single factor analysis method,the effect of rake angle,back angle,cutting edge inclination angle and cutting edge radius on the side direction burr size is analyzed.(2)Suppression method of burr in copper electrode milling.Based on the simulation results,the tool type,material,tooth number,rake angle,back angle,cutting edge inclination angle are designed.The structure of the milling cutter is optimized.The left-hand round-angle burr-suppress milling cutter is developed.The tool test electrode is designed to test the proposed milling cutter preliminarily.Based on the left-hand round-angle burr-suppress milling cutter,the burr suppression machining process for copper electrode of precision mould is established.(3)Test of burr suppression in mould copper electrode milling.The machining process test electrode with typical characteristics is designed.The conventional processing method and the burr suppression processing method are respectively used for machining.The effectiveness of left-hand round-angle burr-suppress milling cutter and burr suppression machining process is verified.Another test electrode with a large number of the same characteristics is designed.The influence of cutting time on burr size is studied.The burr-suppress life of left-hand round-angle burr-suppress milling cutter is obtained.