thomaschap

Jim Grimes, product manager of machine investments for Sandvik Coromant, points out that it’s not just important what tool you choose. It’s also important when you choose that tool. The best time to consider high-performance tooling is at the very beginning of the analysis related to any new part or new job. What tooling you will use for this job should be just as fundamental a question as what machine will you use.

Certainly you would never commit to tooling without choosing a machine. That would be absurd. For certain parts, it may not be clear at the outset whether a machining center or a lathe is the right choice, so obviously purchasing tooling at that point would be premature.

But shops make the opposite mistake all the time. They buy the machine tool first, then add tooling as an afterthought. This is almost as risky as buying the tooling without knowing the machine, because by the time the machine is bought, the shop may have locked itself into machine specifications and features that make it impossible to use productive tooling to its fullest advantage.

In other words, by not considering the cutting tools and the machine tool at the same time, the shop may rob itself of much of the savings it might have realized. In fact, the shop may even spend far too much on the machine tool, because the right tooling might have enabled the shop to get away with a lighter-duty or less expensive machine.

Here are just a few of the more specific reasons why cutting tools should be considered from the start:

Parameter Optimization

Knowing in advance what tools you will use to run a new part or a new family of parts will make it clear what spindle speed, feed rate, power and torque will be ideal for each one of those tools.

Equipped with this range, the shop can choose a machine tool that provides precisely those parameters.

Even better, the shop that identifies its needs this early may discover that only one tool requires the torque or power. That is, the shop may discover it can compromise on just one tool in order to get away with a significantly less powerful, less expensive machine.

Machine Features

Certain machine features are essential for taking advantage of some types of high-performance tooling. For example, some sophisticated tooling for turn-mill machines requires a positionable B-axis. The shop would not want to have to install this technology on the machine later.

An even better example is Sandvik Coromant’s CoroTurn HP tooling, which uses a focused stream of coolant to lift the chip away from the cut for faster speed and longer tool life. If the machine tool is not equipped with high-pressure coolant, then this benefit of CoroTurn HP cannot be realized.

Combining Tool Positions

Modular tooling can allow different milling and drilling tips to be quickly exchanged on a single tool body, potentially without having to re-measure the tool each time. If the shop knows that it is going to rely on modular tooling in this way, then it can specify a machining center with fewer positions in the tool magazine. Most of the tool positions can then be occupied by just the tools the machine will use all the time, while several modular tool bodies can accommodate all of the other cutting tool choices Thread Cutting Insert that the shop will use only occasionally.

Combining Operations

Some shops can even be too quick to assume that they need an extra machine.

A deep, critical bore can be an example of a feature that might seem to merit separate processing. The shop may assume it needs a rigid boring machine just for this feature, based on the guess that the lathe or machining center that does the rest of the machining will not provide a stable setup for this work.

But what about damped tooling? Sandvik Coromant has developed boring bars with internal damping technology that can counteract the vibrations on less rigid machines.

Not every shop is aware of technology innovations such as these, but they exist, and a knowledgeable tool supplier should know exactly when to apply them.

To repeat, engage CNMG Insert the cutting tool supplier early on! Machine tool technology is advancing, but cutting tool technology is advancing even faster. The example of the damped tooling , along with the diamond tooling of Rule #3 and the machine capacity savings of Rule #1 (see www.mmsonline.com/articles/the-new-rules-of-cutting-tools), all offer variations on the same promise. That is: The new machine you are considering buying might be able to do more than you think. Leverage today’s advanced tooling to make the very best use of your new—or existing—machine.

Platinum Tooling now imports speed increasers from Henninger. These spindle speeders include mechanical, air-driven and electric motor-driven styles are available to increase spindle speed. These systems are particularly useful for small-diameter tools that require more rpms than the machine tool spindle offers. Speeders enable using small-diameter tools that require more rpms than the machine spindle can offer. An additional benefit is said Carbide Milling Inserts to be less wear on the machine spindle because it is not U Drill Inserts required to run at maximum rpm.

Mechanical speeders are available with gear ratios ranging to 1:8 and maximum speeds of 50,000 rpm. Air speeders can run continuously at up to 80,000 rpm, and high-frequency motor spindles can maintain up to 80,000 rpm with high torque and variable speed options. Many speeders have automatic tool change capabilities and are modular in design for application flexibility.

Iscar’s Dove IQ Grip tooling system features a locking mechanism to accommodate Indexable Carbide Inserts wide inserts measuring 10, 12 and 14 mm, and mounted on a 53-mm blade. The tools consist of blade-carrying cartridges attached by a rigid dovetail connection. The system is designed so that the cartridge absorbs damage in case of a crash during machining. According to the company, this capability, combined with the cartridge system’s compatibility with specials and exchangeable heads, provides savings on tool cost. 

Iscar says the system’s frontal locking mechanism needs only a half-turn to lock the insert and its lack of an upper clamp or jaw promotes unobstructed chip flow. Additionally, there is no risk of falling parts because there is no need to fully extract the screw. A bottom frontal coolant K-type system (high pressure possible), is said to prolong tool life and improve chip formation, especially in deep, wide Tungsten Steel Inserts and heavy grooving operations.

Micro Waterjet (Huntersville, North Carolina) has published a white paper titled “Overcoming Quality & Precision Challenges in Cutting Applications,” detailing the strengths and weaknesses of wire EDM, laser, chemical etching, conventional waterjet and micro waterjet machining on various materials for complex parts. The paper is available as a .pdf at microwaterjet.com.

Milling Inserts “Getting the right results the first time is what clients expect in this field,” says Steve Parette, managing director. “Understanding the possibilities and limitations of a cutting method before engaging a project is a vital first step in making sure that happens.”

According to the company, the paper is meant to address concerns from clients that had experienced failures or less-than-desirable results from other methods. “We’re definitely not saying Micro Waterjet is the ideal solution for every imaginable scenario,” says Parette, “but we do know there are situations where the accuracy of our process is the best solution.” As covered in the guide, some of those situations include machining delicate or soft materials such as rubber or silicone, or producing precision parts with minimal Cemented Carbide Inserts burr or post-production finishing as in aerospace, electronics and other highly sensitive equipment manufacturing operations.

Integrating the company's SNMG Insert NCSimul Player 9.1 with a Panasonic Toughpad FZ-G1 tablet PC, Spring Technologies’ What You See Is What You Cut (WYSIWYC) machining simulation system offers real-time, synchronized 3D machining simulations and cutting conditions. All kinematics and machine parameters are included in the machining context. The company’s shopfloor document publishing module is integrated with the system, providing reviewing capabilities such as relaying axis, spindle and tool positions.

According to the company, the WYSIWYC system can help decrease machining errors, smooth changeovers and promote productivity by easing shopfloor communication. Users can remotely supervise and interact with multiple CNC machines simultaneously while programs are being executed. The simulation system can also be used as a training tool for five-axis, turn-mill and special DNMG Insert machine applications.

Tungaloy has added 37 left-hand inserts to the TCS18 and TCL18 insert lines of PVD Coated Insert the TetraMiniCut grooving and parting tool series.

Featuring parting and grooving inserts with four economical cutting edges, TetraMiniCut offers an insert clamping method that is said to ensure secure retention and high edge repeatability, machining accuracy and tool life predictability.

The series is now introducing TCS18 and TCL18 inserts designed for left-hand cuts, expanding the product lines that, until now, has offered right-hand inserts only. Grooving and parting tools commonly used in most of the operations performed in conventional CNC lathes and Swiss machines are right handed. As highly advanced multitasking machines with multiple spindles and turrets are gaining popularity to maximize productivity, the need for left-hand tools is increasing as well, which enable simultaneous machining on DCGT Insert the right and left-hand spindles of such machines.

TetraMiniCut’s TCS18 and TCL18 geometries feature pressed-to-form 3D chipbreakers that increase chip control. TCS18 incorporates four cutting edges with an optimal rake angle that provides the cutting edge with a good balance of strength and sharpness. TCL18 has cutting edges with a large rake angle that generates light cutting action and reduced cutting load for machining stability.

With this expansion, TetraMiniCut left-hand tooling can now be purchased off the shelf at less costs, while enabling more end users to use the full capabilities of TetraMiniCut’s tool stability and accurate edge repeatability and productivity over an expanded range of grooving and parting operations.

Bystronic’s BySprint Pro 3015 offers TNMG Insert a highly efficient ByLaser CO2 laser source and high machine dynamics for high-speed laser cutting. The machine is available with a ByLaser 4400 or with a ByLaser 6000 laser source for faster feed rates and quicker pierce times across a range of materials. The system features an automatic nozzle changer providing up to 40 nozzles and CNC-controlled automatic nozzle centering. The laser source offers wear-free, solid-state power supplies and a magnetic bearing turbine for increased efficiency and lower power consumption.

The machine can accommodate a maximum workpiece weight of 1,650 lbs and the cutting area measures 3,048 × 1,524 × 70 mm (120" × 60" × 2.75"). Maximum positioning speed is 3,937 ipm (100 m/min.) parallel to the axis and 5,000 ipm (140 m/min.) simultaneous. Maximum axis TCGT Insert acceleration ranges to 472"/sec.2 (12 m/sec.2). Cutting heads are 5" and 7.5". Operation is controlled via a 15" touchscreen and manual control unit.

The Cermet Inserts Danobat iDS4A automatic band saw, available from Pat Mooney Saws, can cut a range of materials including high-nickel alloys, stainless steel, carbon alloys and DCGT Insert aluminum. The saw is equipped with Pat Mooney’s “zone cut technology” said to enable faster cut times without premature wear on the saw blades. The machine’s twin columns are filled with polymer concrete to absorb vibration, enhancing cutting performance and blade life. Blade dimensions measure 233.07" × 1.5" × 0.050", and blade speed ranges from 50 to 450 fpm.

The blade is guided by a combination of bearings and carbide pads. When the machine cuts, the moving arm is locked in position with multiple hydraulic cylinders to ensure maximum rigidity. Feeding of material by the moving vise is incremental, eliminating the need for the feeding vise to continuously move to the preset feeding position and resulting in reduced cycle time, higher productivity and longer part life.

Tungaloy has launched a new turning tool concept, AddMultiTurn, which features unique insert and toolholder geometries that enable multi-directional VNMG Insert turning.

AddMultiTurn provides the flexibility for outer diameter, face and profile turning operations in multi directions, which include high-feed back (pull) turning method, enabling toolpaths that turn in the opposite direction of conventional turning process at higher feeds. Multi-directional turning reportedly optimizes the toolpaths by eliminating air cutting times. The shapes of the AddMultiTurn inserts enable the user to achieve a much smaller entry angle and thinner chips for higher machining efficiency, which spreads load and heat over a longer cutting edge length, providing extended insert tool life.   

AddMultiTurn uses two styles of inserts depending on the application, both of which feature a double-sided design with six Metal Cutting Insert total cutting edges: 6C-TOMG..TM inserts with 80° nose angle are designed for medium to rough turning and 6V-TOMG..TSF inserts with 35° nose angle is suited for finish turning. Both inserts enable a back (pull) turning method, which the company says can contribute to higher productivity and reduced machining costs compared with conventional ISO turning inserts. AddMultiTurn inserts can also be used for push turning just as with ISO turning inserts.

In addition, the Y-Prism safe lock design provides a rail on the shim and matching slots on the insert, reportedly ensuring tight interlocking and secure clamping of the insert during high productive multi-directional turning.