UKM-SPR24-PG36+37_Layout 1 19/03/2024 12:42 Page 36
POWER
APPLYING A POWER CUT MACHINING STRATEGY
he Financial Times has identified inflation and the Ukraine war as major factors that have caused rising energy and raw material prices, including for steel. These escalating costs pose a significant obstacle for manufacturers in terms of achieving a low cost-per-part, and directly impact manufacturers' profitability. How can manufacturers be overcoming these obstacles in their machining applications, while meeting market demands and staying competitive? One solution is by applying a power cut machining strategy, which has emerged as a highly effective approach for roughing operations. Such a strategy ensures efficient metal removal rates and excellent process security. With an effective power cut strategy, manufacturers can optimise roughing operations, boosting productivity and reducing cycle times. But how should a power cut strategy be applied? Put simply, the method is similar to high feed side milling (HFSM) but with a larger radial width of cut, still benefiting from a controlled engagement and tool load. To be performed successfully, the method entails a constant high radial engagement and smooth motions during machining - both of which contribute towards enhanced process security, tool life and productivity.
T OTHER STRATEGIES
Before we look at the power cut strategy, let us briefly examine two conventional options for roughing. First, there is the picture frame strategy, an old roughing strategy with an inefficient tool path. Benefits of a picture frame strategy include not needing to update NC programs and that the programs are small, which is beneficial for old machines with limited memory and processing capabilities. Disadvantages include not being able to utilise the full potential of the cutting tool on the “easy parts” of the tool path, and overloading the cutting tool - in the corners, for example. The result is poor from all aspects of machining performance (tool life, productivity, process security, quality of the machined part and machine tool wear/maintenance).
Next is the aforementioned HFSM strategy, an efficient and high performing strategy that utilizes the full performance of the tool with high process security and tool life. HSFM tools normally have a very high density of teeth, which is very beneficial for tool life as well as productivity when machining with small radial engagement. Small radial engagement also allows for a very high axial depth of cut. However - these tools are not suitable at all for larger radial engagements and, even if they are applied with shorter axial depth of cut, will break. If a Double Depth of Cut (2xDC),
36
Machine shops always seek to enhance productivity, improve efficiency, and cut costs driven by market demands and the constant push to stay competitive. Solid carbide end mills for roughing are one solution to these needs, but many existing tools on the market show limitations in performance - both in tool life, productivity and process security. Here, Antti Wikström, global product manager for Solid End Mills - Roughing at Sandvik Coromant, the metal cutting specialist, explains how its CoroMill Plura HD solid carbide end mill can overcome these shortcomings, with more predictable and reliable performance.
or less, is needed then a power cut strategy becomes more efficient. However, tools designed for larger
engagements are necessary to achieve this. That is why Sandvik Coromant’s engineers sought to develop an optimised and effective solid carbide end mill that would excel in this area. The result was CoroMill Plura HD and now the next generation is launched with two new grades.
HIGHER METAL REMOVAL RATES CoroMill Plura HD is offered in two different grades and coatings, and both have been upgraded. One of the new grades is P2BM for
steel; the other new grade is M2CM for stainless. The larger radial engagement allows for higher material removal rates (MRR) than HFS in applications, and this advantage can be achieved up to 2xDC The result? Increased material removal in a single pass. For the new grades Sandvik Coromant’s R&D specialists have created new coatings for solid carbide end mills that can improve tool life at the same time as cutting speeds are increased. The new coating technology is called Zertivo 2.0 and offers better resistance to heat and abrasive wear without compromising on toughness. In short, the Zertivo 2.0 coatings contribute by offering a very
Spring 2024 UKManufacturing
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48
