Requirement
(1) Quality Tooling
Quality
Tooling Is A Necessary Requirement To Achieve And Maintain
Optimized Machining Conditions.
Definition
For A Quality Tool:
1.
Reasonably Priced. (the most expensive is not necessarily
the highest quality)
2.
Product Consistency. (optimized machining requires
a consistent tool)
3.
Product Service. (the best tool in the world is not
worth anything if the manufacturer can't support you)
4.
Specially Designed Tooling. (utilizing special tooling,
designed to fit the application, can yield a multiple increase
in productivity levels and a lower cost per part)
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Requirement
(2) Proper Machine Condition
Proper
Machine Maintenance, And Matching Machine Capabilities To
The Operation, Are Required For The Success Of Any Machining
Operation
Proper
Machine Condition List:
1.)
Maintain machine to original operating specifications.
(determine machines capabilities)
a.
Set up maintenance program and maintain on a regular basis.
b. If it breaks, fix it the right way, the first time.
c. Better yet, fix it before it breaks.
2.
Match machine to operational requirements. (utilize
the machine's best characteristics)
a.
Rigid machines should be used for the heavy machining
operations.
b. Fast machines should be used for light matching of
multiple operations.
c. Make sure machine has the physical capabilities for
the job. (i.e. HP)
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Requirement
(3) Simplicity of Operation
There
is No Substitute For Simplicity, Complexity Adds Difficulty
To Optimization
Simplicity
List:
1.)
Simplify setup for operation. (optimized machining
includes setup time)
a.
Standardize setup or setup procedures.
b. Make sure setup meets operational requirements. (i.e.
rigidity)
2.
Use common sense and simplicity to organize the sequence
of operations. (create better flow)
a.
Don't chase your tail around the shop.
b. Product consistency can be maintained better with simplified
operations.
c. Break up multiple operations if necessary. (may also
improve through-put)
3.
Don't sacrifice any of the Seven Requirements. (you
will lose more than you gain)
a.
Use them as a guide to simplicity.
b. If one of them is lacking, it is costing you money.
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Requirement
(4) Rigidity
Tool
Life, Cycle Times, And Product Through-Put Can Not Be Optimized
Without Rigidity
Rigidity
List:
1.
Machine rigidity. (must evaluate capability)
a.
Make sure the machine has the proper rigidity for the
operation.
b. Anti-backlash required on axis feeds for climb machining.
(best tool life)
2.
Part piece and setup rigidity. (evaluate best configuration)
a.
Evaluate part configuration and machining orientation.
b. Design setup for maximum rigidity. (reduce number of
operations if necessary)
3. Tooling
system rigidity. (evaluate for maximum rigidity)
a.
Use the largest diameter and the shortest length of tool
possible.
b. Use a tool holding system designed for rigidity and
the shortest overhang allowed.
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Requirement
(5) Proper Speed To Feed Relationship
Metal
Removal Rates Can Not Be Optimized If The Proper Speed To
Feed Relationship Is Not Achieved
Proper
Speed To Feed Relationship Requirements:
1.
Relationship too far apart (poor tool life)
a.
Speed too high and feed too low causes high frictional
heat and rapid edge wear.
b. Adjust by bringing speed down first, increasing feed
may cause tool to break if speed is too high and out of
proportion for application.
2.
Relationship too close together (catastrophic failure)
a.
Feed too heavy for tool structure and causes tool to shatter,
possibly damaging part piece and tool holding system.
b. Adjust by bringing feed down first, in case speed is
also too high.
3. Determining
proper relationship (work with application)
a.
Start with a moderate speed for given application. (can
not work with relationship if speed too high on first
pass)
b. Start with medium feed and work up until machining
conditions indicate relationship getting too close together
(chattering), then back off 10% to 20% on feed. (this
established optimum feed)
c. Increase speed and feed proportionately upward 10%
to 20% at a time, until machining conditions indicate
you have reached the upper limit for the application.
(chattering, poor part finish, excessive vibrations)
d. Reduce speed and feed proportionately downward by 20%.
(established optimized machining rates with safety factor)
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Requirement
(6) Proper Cutting Fluid
Improper
Cutting Fluid Or An Inadequate Amount Of Cutting Fluid Can
Cause Premature Tool Failure
Proper
Cutting Fluid Selection:
1.
Running dry. (very poor tool life)
a.
Don't ever run dry, unless you have to for safety's sake.
b. If you must run dry, keep speed on the low side (but
not too low) and feed on the high side. (keeps frictional
heat low and maintains heat in chip formation)
2.
Water based coolant (for heat generating applications,
water absorbs heat better than oil)
a.
Use in applications, such as with finishing end mills,
where light chip loads are common. (light feeds transfer
more heat into the cutting tool)
b. Flood systems are much more efficient than mist. (mist
systems must be positioned precisely to work properly)
3. Oil
based coolant. (for heavy feed applications, oil does
not absorb heat very well)
a.
Use in heavy feed applications, such as with roughing
end mills, where high chip loads are common. (thicker
chips absorb heat better but need more lubricant to produce
b. Chilled high pressure systems work better than flood.
(only if machine is enclosed, with mist extraction system)
4. Natural
vegetable oil lubricant. (for heavy feed applications
only, not a coolant)
a.
Can be used as a replacement for oil based coolant applications.
(it typically has a lubricity level 3 times that of oil
based coolant, and is biodegradable)
b. Mist system is all that is typically required. (very
expensive otherwise)
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Requirement
(7) Operator Training
Operator
Training Is Essential in Achieving And Maintaining Optimized
Machine Applications
Operator
Training Areas:
1.
The operator must be a direct part of the optimization
attempt for it to succeed. (he or she is the one who
has to maintain it from now on)
a.
Draw on the operator's experience. (no one knows their
machine better)
b. Take the operator's advice on machine capability and
required machine maintenance requirements. (will help
you a lot in the early stages)
c. If they own it, they will take care of it. (you'll
know they'll keep it going when you're not around)
2.
The operator must know the differences between what they
have been doing for years, and an optimized application,
and how it reacts to changes. (machining conditions
at elevated speeds and feeds react differently than those
at lower speed and feed ranges)
a.
They must clearly know how the operation functions and
reacts. (sound and feel)
b. They must also know how to adjust the application properly,
if something changes (nothing is ever 100% absolutely
the same)
3. You
must also train them, and yourself, to work together to
achieve this common goal. (if you can not work together
and trust each other, the operation will definitely fail,
and everyone loses)
a.
To error is human, grow from your mistakes.
b. Not to train properly, or in some cases not to train
at all, would be inauspicious.
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Niagara Cutter, Inc.
• 200 John James Audubon Pkwy • Amherst, NY 14228 USA