ShopSolutions
By itself, moving from HSS to carbide would enable much higher machining rates and extend edge life. “The re- placeable tip design, moreover, would minimize the amount of carbide used and enable in-spindle tip replacement. The carbide shank, which was reusable, would stiffen the cutting system for a better finish on the wear surfaces of the teeth,” said Thornburg.
During trials, Stoddard and Thornburg worked together to optimize parameters for the new process. They decided to quadruple the surface speed and double the feed rate, and to take just one roughing and one finishing pass. Final settings for the 1" (25.4-mm) tool are 1500 rpm, 0.060" (1.5-mm) depth of cut for roughing and 0.010" (0.25 mm) for finishing. This process change reduced cycle time for the teeth from 28 to 11 minutes.
Once the new process went operational for a couple of
months, tool life could be compared. The Chip-Surfer tips typically last through 50 pieces in this application, while the gear gasher needed a regrind every 10–20 pieces, reduc-
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ing stoppages for tool replacement and cutting tool inventory costs as well.
Even though it is form matched, the Chip-Surfer tip costs about $125 apiece, the same as one regrind on the gasher. Keeping spares is much more economical, too, because a single gasher can cost more than $400 and $100 a pop to regrind and can take weeks for delivery. Bottom line: tooling cost per part dropped from $20 to $2.56, an 8 to 1 reduction.
Sector gear, machined from solid 17-4PH bar stock, looks like half a gear with a lever arm attached. Measuring about 3½" (89-mm) diameter with 46 teeth over a 180° arc, the gears produced by ASPI go into helicopter flight controls.
The improvement in throughput stems from the proven ca- pability of carbide over HSS, plus the Chip-Surfer’s free-cutting presentation geometry that enables higher feeds and speeds without chatter, said Thornburg. The Ingersoll Chip-Surfer mill features a replaceable carbide chip that screws onto a threaded shaft with 0.0002" (0.005-mm) repeatability to datum. Tips can be swapped out right in the spindle. The shaft can be either alloy steel or carbide depending on stiffness requirements and impact loads. “Even with the carbide shaft, the only throwaway carbide is the tip,” said Thornburg. Ingersoll custom-grinds a standard Chip-Surfer T-Slot tip to match ASPI’s required form. Modified standard Chip-Surfers are very common for slotting and T-slotting and die and mold applications. “As in the ASPI case, it’s a simple matter of a custom grind on a standard Chip-Surfer T-slot tip, which is always available off the shelf,” said Konrad Forman, Ingersoll’s national milling product manager. ME
For more information from Ingersoll Cutting Tools, go to
www.ingersoll-imc.com, or phone 815-387-6600.
44
ManufacturingEngineeringMedia.com | June 2013
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