Chọn dao phay phù hợp cho từng loại vật liệu - Bảng tra cứu

# Chọn Dao Phay Phù Hợp Cho Từng Loại Vật Liệu Việc chọn dao phay đúng là yếu tố quyết định chất lượng gia công và tuổi thọ dao. ## Bảng Tra Cứu Nhanh ### Aluminum 6061: ``` Roughing: End mill 3-4 flutes, uncoated Finishing: End mill 2 flutes, polished Speed: 8000-15000 RPM Feed: 1500-3000 mm/min Coolant: Flood coolant hoặc air blast ``` ### Steel 1045: ``` Roughing: End mill 4 flutes, TiN coated Finishing: End mill 2-3 flutes, TiAlN coated Speed: 3000-6000 RPM Feed: 800-1500 mm/min Coolant: Flood coolant bắt buộc ``` ### Stainless Steel 304: ``` Roughing: End mill 3 flutes, sharp edge Finishing: End mill 2 flutes, positive rake Speed: 2000-4000 RPM Feed: 600-1200 mm/min Coolant: High pressure coolant ``` ### Titanium Ti-6Al-4V: ``` Roughing: End mill 3 flutes, very sharp Finishing: End mill 2 flutes, polished Speed: 1500-3000 RPM Feed: 400-800 mm/min Coolant: High volume flood ``` ## Chi Tiết Theo Vật Liệu ### 1. Aluminum Alloys #### Đặc Điểm: - **Soft** và **gummy** - **Chip evacuation** quan trọng - **Built-up edge** dễ xảy ra #### Tool Selection: - **2-3 flutes** cho chip clearance - **Sharp cutting edges** - **Polished flutes** chống stick - **Large helix angle** (45°+) #### Recommended Brands: - Harvey Tool (USA) - Onsrud (USA) - Kyocera (Japan) ### 2. Carbon Steel #### Đặc Điểm: - **Work hardening** nhanh - **Heat generation** cao - **Chip control** cần thiết #### Tool Selection: - **4 flutes** cho surface finish - **TiN/TiAlN coating** - **Variable helix** chống chatter - **Chip breaker** geometry ### 3. Stainless Steel #### Đặc Điểm: - **Work hardening** rất nhanh - **Gummy** và **stringy chips** - **Heat resistant** #### Tool Selection: - **Sharp edges** bắt buộc - **Positive rake angle** - **Uncoated carbide** hoặc **PVD coating** - **Constant feed** để tránh work hardening ## Coating Selection Guide ### Uncoated Carbide: - ✅ Aluminum, Copper - ✅ Plastics, Composites - ❌ Steel, Stainless ### TiN (Titanium Nitride): - ✅ General purpose steel - ✅ Cast iron - ⚠️ Aluminum (có thể stick) ### TiAlN (Titanium Aluminum Nitride): - ✅ High-speed steel machining - ✅ Stainless steel - ✅ High-temp applications ### Diamond (PCD): - ✅ Aluminum (high volume) - ✅ Composites - ❌ Ferrous metals ## Geometry Considerations ### Helix Angle: - **30°**: General purpose - **45°**: Aluminum, soft materials - **60°**: Finishing operations ### End Mill Types: - **Square End**: General milling - **Ball End**: 3D contouring - **Corner Radius**: Strength + finish - **Tapered**: Deep cavities ## Troubleshooting Guide ### Poor Surface Finish: - ✅ Increase speed - ✅ Decrease feed per tooth - ✅ Check tool sharpness - ✅ Improve rigidity ### Tool Breakage: - ✅ Reduce chipload - ✅ Check work holding - ✅ Verify speeds/feeds - ✅ Improve coolant flow ### Built-up Edge: - ✅ Increase cutting speed - ✅ Use sharper tools - ✅ Better coolant - ✅ Reduce feed rate ## Cost Optimization ### High-Volume Production: - **PCD tools** cho aluminum - **Ceramic inserts** cho cast iron - **Indexable** end mills ### Prototype/Low-Volume: - **Solid carbide** end mills - **General purpose** coatings - **Standard geometries** Các bạn có kinh nghiệm gì về chọn dao? Share tips nhé!