أدوات تشكيل الكربيد الأسمنتي، الشائعة في التصنيع الحديث، تلعب دورًا أساسيًا في الإنتاج بفضل مقاومتها الممتازة للتآكل وكفاءتها العالية. هذه الأدوات لا تُحسّن كفاءة الإنتاج فحسب، بل تضمن أيضًا دقة وجودة المنتجات.

Cemented carbide forming tools enhance production efficiency and precision, with specialized tools supporting various manufacturing processes. Commonly referred to as spindle shaper cutters, they are widely used in woodworking spindle shapers, four-sided planers, surface planers, and thickness planers for shaping and edge trimming. Typical carbide forming tools include straight knives, pre-milling cutters, grooving tools, edge banding knives, and a series of cutters designed for specific applications, such as four-sided planer trimming knives, 1/4-radius roundover cutters, and finger joint cutters. Together, these tools form a comprehensive system that strongly supports industrial production.

 

Structure of Forming Tools

A tool consists of a cutting edge and a body. The flexible design of the cutting edge adapts to different processing requirements. Carbide forming tools are mainly composed of two parts: the tool body and the cutting edge, whose structure is shown in Figure 1. The shape design of the cutting edge is flexible and diverse, which can meet different processing needs, while the tool body is designed accordingly based on the shape of the cutting edge to ensure the overall performance of the tool.

 

Design Principles and Processing Technology of Forming Tools

The process of forming tools is complex, with flexible design that must undergo strict inspection. Carbide forming tools feature highly flexible designs; by adopting cutting edges with different patterns, they can easily machine a variety of patterns. Their cutting performance is stable and the cutting speed is high. In terms of processing technology, forming tools need to go through a series of tedious procedures, including blanking, lathe turning of the tool body, slot milling, welding, surface treatment, grinding of the cutting edge, and cleaning and packaging. In addition, woodworking forming tools must undergo multiple fine inspection procedures during processing to ensure the quality and performance of the final product.

 

Storage and Transportation of Forming Tools

Safety is crucial. Packaging and storage must prevent damage, and sponge pads and packaging should be properly handled. The cutting edges of forming tools are extremely sharp and fragile, so extra care must be taken during transportation, installation, and disassembly to ensure the cutting edges remain undamaged. To ensure the safety and convenience of tools during transportation and storage, it is recommended to place thick sponge pads inside the box for packaging to protect the cutting edges. Meanwhile, please note that neither the sponge pads nor the boxes inside should be discarded at will. During storage when tools are not in use, the following points should be noted to maintain their optimal condition:
① Different tools should be stored separately to avoid mutual collision;
② Protective pads must be used to prevent direct contact between cutting edges and hard objects;
③ After use, tools should be thoroughly cleaned of wood chips and dirt from inner holes and both bearing surfaces, coated with anti-rust oil, and then placed back in their original packaging.

 

Specific Applications of Forming Tools

Rotation Direction and Cutting Parameters

The rotation direction follows specific principles, and cutting parameters must match the material and tool specifications. The rotation direction of forming tools is crucial, as it directly affects the tool’s performance and service life. During installation and use, it is essential to follow the direction indicated in the diagram to ensure that the tool can complete forming tasks efficiently and safely. Figure 2 shows the rotation direction of forming tools.

The following method can be used for quick identification:

(1) “Large-end up, counterclockwise”: Take the end of the tool with a larger cutting diameter as the reference surface. Following the principle of “large-end up, counterclockwise” means placing the large-diameter end of the tool facing upward and rotating it counterclockwise.

(2) “Small-end up, counterclockwise”: Take the end of the tool with a smaller cutting diameter as the reference surface. Following the rule of “small-end up, counterclockwise” means placing the small-diameter end of the tool facing upward and rotating it counterclockwise.

In the cutting process of forming tools, selecting appropriate cutting parameters is crucial. Firstly, the proper cutting speed should be determined according to the material being processed. Then, based on the tool diameter and the selected cutting speed, the range of the tool’s rotational speed is further determined or calculated. Generally speaking, the larger the tool diameter, the lower the rotational speed, and vice versa. In addition, the formula for calculating cutting speed is also an essential reference.

 

Installation, Debugging, and Usage Precautions

Strictly follow the installation procedures to ensure safety and avoid deviations during processing. Before installing the tool, it is necessary to clean up debris on the spindle, keep the tool mounting surface clean and flat, and ensure that the safety guard of the tool is installed. Strictly control the fit tolerance between the tool’s inner hole and the equipment spindle, keeping it within 0.03 mm to ensure that the tool has no deformation and minimal vibration during processing.

Pay special attention to whether the installation direction of the tool is correct, and check for looseness after clamping. After completing the tool installation, conduct a trial run first. If excessive tool wobble is found, stop the machine immediately for inspection. Maintain a uniform feeding speed during processing, and select an appropriate feeding rate according to different processing materials and cutting amounts to avoid forced material pushing.

 

Quality Inspection and Re-grinding

Specialized equipment should be used for re-grinding to avoid damaging the tool shape due to improper operations. During the use of forming tools, re-grinding should be performed promptly if the following situations occur:

① The forming quality of the processed workpiece surface fails to meet the standards;

 

② It is laborious to push the material, and there is a phenomenon of material burning;

 

③ The energy consumption of the machine tool increases significantly;

 

④ The wear of the tool tip reaches 0.2 mm.

 

The following correct methods should be followed when re-grinding forming tools:

① Specialized equipment should be used for sharpening, and hand-held tool sharpening should be avoided;

 

② During the sharpening process, ensure that the grinding wheel surface remains parallel to the cutting edge.

 

Common Problems in Usage

Problems arise from equipment issues or improper operations and require careful investigation. Obvious path on the cross-section of processed workpieces is usually caused by severe machine tool vibration, improper tool installation, unstable reference surfaces, uneven feeding force, and excessive tool runout tolerance. Burning of processed workpieces may result from excessive cutting parameters, severe tool wear, improper use or lack of cutting fluid, etc.

Loose أداة fit with gaps is usually caused by the following factors:

① Improper tool adjustment, inappropriate addition of gaskets, or mismatched tool models;

 

② Unreasonable tool installation methods, such as slag inclusion in the middle or failure to install it in the proper position;

 

③ Deviations between the designed dimensions of the tool and the actual manufacturing dimensions.