April 25 2007
| New Tooling Introduced At Westec 2007 Several new cutters and insert grades were introduced at Westec 2007 that their manufacturers said deliver high performance, durability and long life for milling operations on a many materials including difficult-to-machine and hard materials.
Air Power Spindles For Ultrahigh-Speed Machining New air power spindles address the challenges of micro machining at ultrahigh-speed and with precision by offering variable spindle speeds that run up to 80,000 rpm. These air-driven tools work on existing machining centers, improve surface-finish quality, extend tool life and reduce wear on high-speed spindles.
Solving Spindle Problems Spindles get blamed for a lot of machining problems but, in many cases, the spindle is not the root cause of the problem. A diagnostic tool is available that uses spindle error-motion testing to determine if a spindle is the cause of machining problems, or there is another reason for unwanted spindle motion. This is especially important for attaining high accuracy, and for the production of expensive parts for which machining errors are costly.
Dynamic Analysis Leads To Optimum Cuts Trying to find that elusive optimal combination of spindle speed (rpm) and axial depth-of-cut by trial and error for a given tool and material is similar to looking for the proverbial needle in a haystack. But a dynamic analysis technique is available that helps to pinpoint the optimal cutting parameters of spindle speed and depth-of-cut for a specific tool/toolholder/machine stackup to maximize metal-removal rate while avoiding chatter. The technique is used primarily for milling, boring and turning operations with aluminum, cast iron, steel and high-temperature alloys.
Reducing Chip Problems Chip control is a concern because a buildup can cause hammering and chatter, and has a deleterious effect on cutting forces, surface finish and tool life. Several new inserts, chipbreakers and cutting tools now are available that help to reduce chip accumulation.
Good Tool Geometries Cut Bad Vibrations Reducing vibrations in machining increases tool life, produces better machined surface finishes and prolongs the life of machine tools. In addition, smooth-cutting machines make for a quieter, more pleasing work environment. Most tools are designed for maximum metal removal rates and their designs can make them prone to developing vibrations and chatter. To cope with chatter, newer cutting-tool geometries produce chip loads that are light initially but that increase as the tool or insert bites deeper into the workpiece. This results in removing a sizeable amount of material with a cut, but these new geometries keep the cutting action smooth and progressive without producing heavy vibrations.
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