Superfinishing of hardened steel for the moulding industry of automotive lighting parts

Bruno Sousa , Tiago Silva , Vitor Sousa , Daniel Figueiredo , Cristina Fernandes , Alexandre Ferreira , Abílio de Jesus
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Abstract

Achieving a mirror-like finish surface quality in plastic injection molds and dies is necessary for the manufacture of optical components in the automotive industry. Any defects present on the mold surface will be evidenced on the injected part, compromising the functionality of the final product. Moreover, the typically employed finishing techniques (milling and polishing) in mould steels can be excessively time-consuming. The identification of machining and polishing combinations that meet the demanding surface requirements while minimizing time and material resources is therefore essential for ensuring the efficiency and cost-effectiveness of the mould-making process. In this work, an experimental study was conducted on the milling of hardened tool steel using a 6 mm two flute ball nose end mill. Distinct configurations of axial and radial depths of cut as well as feed per tooth were considered and their impact on the pre-polishing surface roughness was analysed. A methodology for the parametrization of polishing conditions was developed, ensuring consistency of speed and pressure. Further tests were conducted to evaluate the relation between post-polishing surface quality and the total duration of the combined finishing approach. The polishing stage consisted on submitting the milled samples to SiC paper (800 and 1000 grit) and diamond cloth (6 and 3 µm) polishing. The method provided enhanced control of the polishing operation and revealed milling/polishing improved sequences for attaining surface roughness technical requisites.

用于汽车灯具部件成型工业的硬化钢超精加工
实现注塑模具和模具的镜面抛光表面质量是汽车行业制造光学元件的必要条件。模具表面存在的任何缺陷都会体现在注塑部件上,从而影响最终产品的功能。此外,模具钢通常采用的精加工技术(铣削和抛光)耗时过长。因此,确定既能满足苛刻的表面要求,又能最大限度地减少时间和材料资源的加工和抛光组合,对于确保模具制造过程的效率和成本效益至关重要。在这项工作中,对使用 6 毫米双刃球头立铣刀铣削淬硬工具钢进行了实验研究。研究考虑了不同的轴向和径向切削深度配置以及每齿进给量,并分析了它们对抛光前表面粗糙度的影响。制定了抛光条件参数化方法,确保速度和压力的一致性。还进行了进一步的测试,以评估抛光后表面质量与组合抛光方法总持续时间之间的关系。抛光阶段包括对研磨样品进行碳化硅纸(800 和 1000 粗细度)和金刚石布(6 和 3 微米)抛光。该方法加强了对抛光操作的控制,并揭示了研磨/抛光的改进顺序,以达到表面粗糙度的技术要求。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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CiteScore
1.70
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