In the trials, with Hawke’s and Jolley’s guidance, parame-
ters were gradually ramped up to balance removal rates and edge life. In the end, the new cutter nearly doubled the re- moval rate with absolutely no insert fractures. Edges looked as good as new after several passes. Here are the results: Machining on a 20-hp (14.9 kW) Toyoda FV 1680 running at 485 rpm/ 650 sfm (198 m/ min); 0.040" (1 mm) depth of cut; and feed rate of 100 ipm (2540 mm/min), metal removal rate was 10 in.3 cm3
(164
). Using the Gold Quad F high-feed face mill with the same parameters except for feed rate of 120 ipm (3 m/ min) and 0.075" (1.9-mm) depth of cut, metal removal rate soared to 22.5 in.3
(369 cm3 ).
Given the delivery pressures for the mold blocks, Shaw immediately adopt- ed these parameters as standard and monitored the process closely. Cycle times per block dropped from ten hours to six, which helped shave about a week off the delivery schedule. After three days’ experience with the new tool, Shaw operators made two observa- tions: edge life was up 20% longer with no ruptures, and the spindle load was the same as before despite doubling the depth and feeding 20% faster. “This was defi nitely a tool and
process worth applying plantwide,” said Knight. “The same cutter body accommodates a surprising variety of inserts to match different conditions, including contouring.”
Since that initial mold-block job in
February, in fact, Shaw has used 3 and 5" (76 and 127-mm) Gold Quad F face mills for rough milling, both fl at and contour, on a variety of steels and stainless steels. “It has benefi ted our enterprise-wide profi tability way beyond that fi rst job,” said Knight. One recur- ring application has been shanking of forging dies. “Based on what I’ve seen,
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I’m sure we could run this tool at these depths and 180 ipm [4522 mm/min] on many softer steels.”
The Ingersoll Gold Quad F face mill may seem an odd tooling choice for this deep-cut application. Classifi ed as a
Compact Head Design Easy indexing during operation
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January 2016 |
AdvancedManufacturing.org 39
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