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Dynamic Roughing and unlocking the potential of

Multi axis

David Conigliaro

Mastercam Mill Product Line Manager

Traditional subtractive 3 axis Roughing

Dynamic full flute 3 axis subtractive Roughing

Unlocking the potential of Multi axis Conclusion

Traditional Subtractive Roughing

• Start with a material Volume

• Machined with small stepdownsand modest stepovers.

• Most dangerous part of any job

• Tool assemblies can be at risk

• Accessibility, can all areas that require machining be accessed?

Traditional Subtractive Roughing

• Engineered to shear material

• Require heat to plasticize material

• Tool design = target chip load (Hex)

• Geometries improve shearing, chip evacuation, vibration reduction

• Tool performance and tool life depend on feed, speed, and motion to manage chip load (Hex)

• Too much heat destroys protective coating, creates physical damage

6

How Do Tools Perform?

• Love compression, weak when pulled apart

• Tool geometries (helix, edge prep, coating, etc.) target chip thickness and compression required to shear

• Design for chip evacuation

• Quality carbide is KEY!

• Maximize what we can get out of the tool – material removal rate

7

Solid Carbide Tools – Changes

• Chip size is consistent, the same

• Good chip coloration

• Cooler tool temperature, part is cool, yet warmer chips

• Machining sounds good, no chirping or squealing

• Achieving the projected tool life

8

When is a Tool Machining Effectively ?

Dynamic Full Flute Subtractive Roughing

• Start with a material Volume

• Machined with very large stepdownswith small step-ups

• Small or large stepovers

• Utilize Radial Chip Thinning

• Improved Metal Removal Rates

• Increased Tool Life

• Reduced Cycle Times

Dynamic Full Flute Subtractive Roughing

Traditional vs Dynamic Milling

15

Ae = .3”/6mm (60%)Ap = .100”/3mm (20%)

RPM = 3060Vf = 39.1”/1050mmpm

MRR (Q) = 1.17in3/18.1cm3

Ae = .060”/1.45mmAp = .93”/22mmRPM = 3060Vf = 60.2”/1630mmpmMRR (Q) = 3.34in3/51.6cm3

1018 Steel12mm/.5” Carbide

Endmill4 Flutes

FPT = .0032”/.081mmV

c= 400SFM/122mpm

185% MRRIncrease

Multi axis with Subtractive Roughing

• Applicable to all Machining stages from Rough to Finish

• Simple 4 axis rotary to Full 5 axis Mill Turn machines

• Utilize shorter more rigid tooling

• Reduces setup errors

• Reduces setup time

• Reduces cycle times


• Multi axis can be used in all machine shops

• Multi axis does mean simultaneous 5 axis or 4 axis motion

• Positional 3+1, 3+2, 4+1 machining benefits all shops

• Reduces costly fixture design and creation


• Investing in Multi axis or Multi-tasking equipment can be the difference between being awarded a project you bid on or not

• Bidding on a project with a 3 axis machine in mind compared to a Multiaxismachine in mind can lead to very bids.

• Multiaxis equipment will allow for a much faster delivery and turn around allowing you to put more jobs through your equipment while at the same time offering customers faster delivery times in today’s lean manufacturing, inventory, and supply chain management environment.

• Rigid tool assembly is required• Two-point hydraulic holders

• Exact-fit, key lock Weldon

• Verify run-out specs

• All tool assembly mating surfaces must be clean!

22

Tool Assembly and Set up Rules

• Choose the right machine for the right job

• Know the machine limits

• Proper tool/workholding

• Decide on Speed or Power cutting

• Air blast, chip evacuation

• Use your tool suppliers!

• Get trained, get support from your CAM partner

23

Other considerations

Cutting Tools

Raw Materials

Man Power

Machining

Overhead Costs

3-5%

20-25%

70-75%

ToolpathPerformance

CuttingTool

PerformanceMachine

Capabilities

5% Maximum Machining Effectiveness

15+% Savings

$

(8-10%)

powerpoint presentation · powerpoint presentation author: stephanie barbagallo created date:...

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