SHAPING AND RELIEVING OF MILLING CUTTERS BY THE ANODE-MECHANICAL METHOD

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP80-00809A000600290894-8
• Release Decision: RIPPUB
• Original Classification: C
• Document Page Count: 4
• Document Creation Date: December 22, 2016
• Document Release Date: September 29, 2011
• Sequence Number: 894
• Publication Date: March 30, 1950
• Content Type: REPORT

Sanitized Copy Approved for Release 2011/09/29: CIA-RDP80-00809A000600290894-8
COUNTRY
SUBJECT
HOW
PUBLISHED
WHERE
PUBLISHED
DATE
PUBLISHED
LANGUAGE
CLASSIFICATION CONFIDENTTJC~E~iil,^.'i' -----?
CENTRAL INTELLIGENCE AGENCY t3i~1G Y~
INFORMATION FROM
FOREIGN DOCUMENTS OR RADIO BROADCASTS
"1 ~~pp~
CD NO.
USSR DATE OF
INFORMATION 191?9
T
echnological -Machine tools
DATE DIST. ~ Mar 1950
Monthly periodical
Moscow NO. OF PAGES ~
Dec 191+9
SUPPLEMENT
Russian REPORT NO.
du eocueur coeruee urouanoe amcnee rxx eanoeu ocrterr
or rxc uuno anne nrxu rxe emus or unoua aer ee
e. e. c., n aeo u,u aecexre, m raanuu~oe oe rxx eerrunae
or m coenx? re aer eueu m u uuurxouteo rurox a no?
xmno n ue. nnoournoe or nu raxe a noxumo.
Stanki i instr~ent, No 12, 1949-
THIS IS UNEVALUATED INFORMATION 50X1-HUM
SHAPING AND RELIEVING OF MILLING CUTT$RS
BY THE ANODE-MECHANICAL METHOD
~iguree are appended.?
Cutting and grinding oP tools by the anode-mechanical method is already
being practiced at a number of plants. However, because of the lack of ex-
perience in working interrupted surfaces by the anode-mechanical method, con-
cern hsa arisen as to the possibility that working on the cutting edge of a
tool where the greatest current intensity ie concentrated might destroy the
cutting edge.
Experimental work Brae done an a milling machine having a converted spin-
dle (see Figure 1}. The nex spindle has current pick-up rings and is adapted
for securing the tool (i.e., the disk-cathode) to it.
The attachment for rotating the cutters (see Figure 2) is set according
to the number of teeth; for achieving a spiral movement of the cutters a rock-
ing device secured by a spring to a stationary support has been used. The
milling cutter to be shaped and a profile cam nre installed on the same shaft
to assure movement according to the required profile. Rotation of the cutter
is accomp5lehed by hand through a pilot wheel. Profile disks of steel and
cuprite are used for the tool-cathode. All other apparatus and the emulsion
are the same as those used in conventional anode-mechanical cutting and grind-
ing.
Profile templets and micrometers were used as checking tools in conducting
the experimental work.
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 Sanitized Copy Approved for Release 2011/09/29: CIA-RDP80-00809A000600290894-8
As a result of experiments in shaping flat models, it was established that
maximum metal removal takes place at 18 volts, CFO amperes. Correct shape and
finish oP the recess being worked is achieved at 14-16 volts, 15-20 amperes.
When the volt-ampere conditions used in grinding and finishing are loxered, wear
on the disk-cathode is negligible and the width of the recess differs only
slightly from the thickness of the disk-cathode.
Experiments in shaping convex and concave disks almost completely confirmed
the results of the first test. They further demonstrated the possibility of ob-
taining sufficient precision and surface quality when working on rotating work
pieces.
After completing xork on models, experimental xork was conducted on profile
mil]. blanks. Structural steel was used for the mill and cuprite for the disk-
cathode.
From these experiments the following conclusions can be drawn;
An attachment with a master form was used for conducting the experiment.
The disk-cathode was notched for better entrance of the emulsion (see Figure 3).
Whoa operating with the master form attachment the impacts of the disk-
cathode against the mill blank were observed. At the moment of impact, an in-
tensive sparking took place in the electrode gap; at the same time the current
intensity increased sharply to 50-80 amperes, while the voltage dropped approx-
imately 15-20 percent below the voltage of the idling generator. Current im-
pulses gave intensive metal e3ection and a rough surface was obtained on the
work piece, although There was no evidence of wear on the disk-cathode.
This experiment established the Pact that interrupted anode-mechanical
shaping of a work piece is fully possible and that the electrokinematic system
used was satisfactory for the conducting of experimental work.
In the course of further work, it became~neceseary to arrange for smooth
rotation of the work piece and its impactless contact with the disk-cathode.
In the direct-current circuit, the installation of a ballast rheostat ie
desirable to prevent excessive sparking under the current impulses,
For an experiment in the shaping of high-speed steel, a 60-millimeter mill
of that material was selected. The disk-cathode tool had a diameter oP 51.30
millimeters. During the experiment the profiles of the cutter and the diek-
cathode xere checked for clearance by means of profile-mating templates. A
clearance of 0.02-0.03 millimeter was observed. The surface oP the miller which
Lad been worked answered the finish requirements oP classes Q V 4 and p V 5.
The disk-cathode, when checked with a micrometer, showed no apparent wear.
The same experiment was conducted on a concave mill. The results were on-
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2. Precision oP profile within ranges of existing tolerances can be achieved.
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 Sanitized Copy Approved for Release 2011/09/29: CIA-RDP80-00809A000600290894-8
5? The recommended electrical conditions are 10-18 volts, 5_6o amperes
.
Working characteristics at a number of time points during the process should
be described. At the moment oP contact betxeen the xork and the disk-cathode,
s'shoxer oP sparks is effected Prom the electrode gap both in the direction of
disk rotation and in the opposite direction. During the initial moment the cur-
rent suddenly increases to 80-100 amperes, then falls to 10-20 amperes, and fin-
ally to zero ae the master form separates the xork Prom the disk-cathode, The
voltage Palle rapidly as the current is rising, and then comes up to its minimal
value, i.e, 2-3 volts belox that oP the idling generator (Por electrical ma-
chines [ij),
During Pints]. finishing, a small amount oP weak yelloxish sparks is e,~ected
at the moment of contact betxeen the xork and the disk cathode. The current
rises to 20-30 amperes, thereafter dropping suddenly to 9-7 amperes and then to
zero as the xork leaves the disk-cathode, At the same time the voltage decreases
3-~- volts and then rises to its rated value Por the operating speed of the gen-
erator,
The greater the rake angle of the back of the tooth, the sloxer must be the
rotation of the mill. The rate of rotation should be somexhere betxeen 20-g0
revolutions per minute.
Shaping and relieving milling cutters equipped xith metal-ceramic hard-alloy
blades i:ncludea the operations of deep roughing, grinding, and finishing, The
first operation of roughing the cylindrical part of the min o..a __? _...
perPormA3 ~1?h a -W;,otu cylindrical disk. In the second o ~- ~Vyi~~j"g are
part oP the mill profile is xorked and relieved xith a s~Piration the curved
operation the final profile oP the tooth is xorked and thepmilldiskrelieved until
the required surface finish is obtained.
At the moment oP contact betxeen the tooth of the mill and the disk-cathode,
current impulses reaching 60-80 amperes occurred, xhile the voltage fell off 5-8
volts, The metal-ceramic blade xas destroyed by eo poxerPul a current; to correct
this situation, the amperage was reduced.
The surface finish, dimensional accuracy, and other char'acter2stics obtained
xere almost exactly the same as those achieved in working mills of high-speed
steel.
The folloxing conclusions can be dram from the experiments conducted:
1. Mills having metal-ceramic hard-alloy blades can be shaped and relieved
by the anode-mechanical method; hoxever, as shaping under large alloxances (i.e,,
relieving the body of the mill) is an operation of lox productivity, it is nec-
essary to supplement this phase of the operation by mechanical methods, Final
shaping and relieving of mills by the anode-mechanical method is a simple and
productive operation, xhile xorking xith abrasives is extremely difficult,
2. The anode-mechanical process assures the necessary dimensional accuracy,
surface Piniah, and ecocomic expediency, A cuprite disk-cathode should be used
for the tool.
3. The recommended electrical regime is 10-16 volts, 5-40 amperes,
In shaping and relieving mills anode-mechanically, the folloxing conditions
are recommended: peripheral speed of the disk-cathode, 4-8 meters per second;
rate oP mill rotation, 5-10 revolutions per minute during grinding and 20-40 rev-
olutions per minute during finishing,
Shaping and relieving of profile mills having hard-alloy blades opens nex
possibilities for the introduction of high-speed profile milling,
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3. Dtaster form
4. Pendulum
5. Support
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Sanitized Copy Approved for Release 2011/09/29 :CIA-RDP80-00809A000600290894-8