Holroyd EX-series CNC rotor milling machines are designed for high speed, precision and reliability. The EX range begins with the 1EX, a machine capable of milling helical components ranging to 150 mm in diameter, and offers stepped Shallow Hole Indexable Insert increases in capability, right up to the 8EX rotor miller for parts ranging to 850 mm in diameter. Additionally, a “special order” 10EX machine is also available for components exceeding 1 m in diameter. Various custom models are available.
EX machines cut a full-depth groove by traversing the cutting tool through the material at the relevant helix angle while simultaneously rotating the component in the C axis. Accurate synchronization between the axes is maintained via the CNC, with digital drive technology controlling all axis movements. The cutting head is able to remove so much material in one step because the majority of heat generated is transferred to the chips, the company says; these are then removed from inside the machine by means of a conveyor system.
The flexibility of EX-series rotor milling machines Cemented Carbide Inserts means they are equally efficient at producing complex components with helical screw profiles as they are at producing gear parts such as worm shafts. Holroyd says that in all manufacturing environments these machines can improve productivity through a combination of high-speed operation, powerful menu-driven touchscreen CNC programming, quick-change tooling, high-power spindles and rigidity.
The Carbide Inserts Website: https://www.estoolcarbide.com/product/cnmm190624-cnmm646-turning-inserts-high-quality-carbide-cutting-tool-for-machine-tools/
Sowa Tool presents its line of GS toolholders made from 100 percent forged cemented carbide inserts construction. The company says the compression during the forging process increases the holder’s strength. These holders are precision ground throughout and balanced for speeds ranging to 30,000 rpm. The toolholder features DIN coolant through the flange as a standard option. ER collet chuck nut threads are precision ground, not cut, and come complete with a balanced nut. ER collets available as standard and steel sealed are made of an alloy steel over carbon steel. According to the company, the stronger material gun drilling insertsgun drilling inserts enables the collet to hold for longer, resulting in cost-saving cutting tool life.
Reducing CO2 greenhouse gas emissions has become the goal of the world, and now many places are discussing to levy CO2 emission tungsten carbide inserts tax. Due to the emergence of new fields, and people have to adapt to the existing fields, the above requirements also have a considerable impact on the research and development of machining tools. This is because more than ever, there is a need to replace drives, update lighter materials, and save energy and resources. R & D personnel see great potential for design modifications to tools, new coatings, new machining strategies, and digital solutions that respond in real time to a variety of conditions within the existing framework.
The current trend is to use these materials in new light aluminum lithium alloys, which will soon overwhelm traditional cutting tools and occupy an absolute advantage. Therefore, the demand for special high-performance tools for such applications will continue to increase. For example, aircraft tube process inserts parts made of aluminum alloy are usually processed up to 90%. According to the required part geometry, many grooves and cavities need to be milled out of the metal to ensure stability and reduce weight. In order to produce high quality parts economically and efficiently, high speed cutting (HSC) is needed to process the parts, and the cutting speed can reach up to 3 ? 000 ? M / min. Too low cutting parameters will lead to chip accretion, which will lead to rapid wear and frequent tool change. Because of the long running time of the machine tool, the cost is high. Therefore, machine tool operators specializing in aluminum processing have good reasons to require their cutting tools to obtain cutting data and tool life above the average level, as well as extremely high machining reliability.
We have shown how to deal with these complex requirements. The 90 ° milling cutter is equipped with a new type of indexable blade. It uses a new PVD coating, manufactured using the “hipims method.”. Hipims stands for “high power pulsed magnetron sputtering”, a technology based on magnetron cathode sputtering. The unique feature of this physical coating process is to form a very dense and smooth PVD coating, which can reduce the friction and the tendency of chip accretion. At the same time, this method improves the stability of the cutting edge, and increases the resistance of the back face wear, thus achieving the maximum metal removal rate. Field tests have shown that hipims indexable blades have advantages over standard types. Tool life increased by 200%. The demand for high-performance cutting tools for processing aluminum alloy is growing, especially in the aviation industry and automobile industry.
Dynamic milling: a milling strategy focusing on efficiency
Many industries (especially the supply industry) are facing the pressure of improving the processing stability, accelerating the processing speed, reducing the processing cost and ensuring the processing quality. At the same time, the requirements of machining reliability and cost efficiency are also strict for surface quality and dimensional stability. In addition, the demand for lightweight or heat-resistant materials is also growing. However, due to these properties, these materials from the ISO m and ISO s material groups are often difficult to accurately process. Dynamic milling provides solutions for this field, while ensuring production efficiency and machining reliability, which is why more and more metal processing companies rely on this method.
The difference between high performance cutting (HPC) and high dynamic cutting (HDC) is the movement and force of milling cutter. In the high performance cutting process, when the milling tool moves, the cutting depth is relatively small; in the high dynamic cutting process, the CAD / cam control system controls along the path of the tool during the processing of the workpiece shape (Figure 1). This prevents or at least reduces non cutting time. Moreover, the cutting depth of high dynamic cutting is much larger than that of traditional high-performance cutting, that is, the stroke distance is reduced, because the whole tool length can be used.
Figure 1 dynamic milling strategy requires appropriate workpiece, milling tool, machine tool and CAD / CAM system
In the process of high performance cutting, the envelope angle is often very large. Therefore, the force in the process is also very large. This will speed up the tool and machine spindle wear. On the other hand, dynamic milling is characterized by high machining stability and long tool life. Generally speaking, the envelope angle of high dynamic cutting is very small, that is to say, the force of the tool and machine tool is much smaller than that of high performance cutting. Compared with high performance cutting, high dynamic cutting has higher cutting parameters, smaller non cutting time and greater machining stability, so its metal removal rate is very high.
Adaptive feed control: using real-time parameters to optimize cutting parameters
For a long time, automation, digitization and networking technology have been widely used in many metal processing fields, and are very popular. In particular, the hardware and software used to collect and analyze real-time data have made a huge leap in performance. Software tools demonstrate how these tools provide numerous opportunities for optimizing processes (Figure 2). Adaptive feed control analyzes the input data of machine tool in real time and adjusts the machining accordingly. This answers a key question for many users. That is, how to give full play to the benefits of the machine tool without major changes to the process or complex reprogramming? The software can greatly shorten the processing time of a single piece. The software has been integrated with the existing control program, and the data in the program has been applied to the machining process.
Figure 2 dynamically adjust the feed according to the cutting conditions. In this way, the production time of a single piece can be shortened and the processing reliability can be improved
During the first tool cutting, the computer “learns” the idle output of the spindle and the maximum cutting efficiency of each tool. It then measures the spindle output up to 500 times per second and automatically adjusts the feed in each case. That is to say, the machine tool always runs with the maximum feed amount of each tool. If the cutting conditions change (cutting depth, machining allowance, wear, etc.), the computer will adjust the speed and output in real time. This not only has a positive impact on the machining time of the workpiece, but also improves the machining reliability with the optimized milling characteristics. The force acting on the spindle is more constant, and the service life of the cutter is prolonged.
If there is a risk of cutter breakage, the computer will immediately reduce the amount of feed or stop the operation completely. Using our high-end computer processing customers, its processing efficiency has achieved amazing improvement. If the process is compatible, the processing time can be reduced by 10%. We have managed to cut the processing time by another half. When the number is large, it will free up a lot of machining capacity. ” In addition, this method is effective no matter whether Walter tool is used or not. It only needs to meet the system requirements of the machine tool.
Walter’s FW4 and MW4 positive wiper geometries are designed for longitudinal turning and facing. They combine a “wiper effect” Carbide Milling Inserts and the wear-resistant Walter Tigertec Gold grades.
The curved wiper cutting edge makes the wiper action universal across various material groups such as steels, stainless steels, cast irons or even super alloys. The wiper action can reportedly be used to reduce machining time by using double the feed rate, while imparting the same surface finish. According to Walter, feedrate increases of up to 300% were successfully utilized, in some cases.
The FW4 universal wiper geometry with a narrow chip breaker, which generates short chips, is for finishing operations. The machining parameters for the FW4 geometry are a feed of 0.0012"-0.020" and a cutting depth of 0.004"-0.100". The primary application is turning steel, stainless steel and cast iron (ISO P, M and K workpiece groups), and the secondary application bar peeling inserts is turning super alloys (ISO S workpiece group).
The MW4 universal wiper geometry features an open chip breaker groove and longer radius wiper cutting edge for high feeds is for medium machining. The machining parameters for the MW4 geometry are a feed of 0.005"-0.022" and a cutting depth of 0.020"-0.180". The primary application is turning steel and cast iron (ISO P and K workpiece groups), and the secondary application is turning stainless steel and super alloys (ISO M and S workpiece groups).
Because of the wiper edge’s curved design, improved surface quality, productivity and process reliability are achieved even when the machine tool is not aligned 100% precisely, such as if the turret is slightly offset. The new chip breakers also increase the chip breaking range, resulting in less machine downtime caused by the creation of bird nests.
Wood drill bits are the main topic of this article. Plus, we will share some useful tips for efficiently drilling out satisfactory holes in wood. Before you put up a cabinet or shelf, we genuinely hope these tooltips herein we share will be a helping, in spite of they are not in-depth.
No matter in common or special carpentry, you will find out wood is quite a whole different story from metal. Say softwood, a sort of timber that consists of cells in which there is a large amount of air making it “soft”, they could get deformed during drilling with ease. Apart from softwood, hard wood’s processing could be a little bit demanding as well. Although without puffs and with dense structure, hardwood is born with cracking. Specific designs and cares are required for wood drilling bits to handle all hindrances.
Suitable Materials according to Wood Types
Generally, for wood hole drilling, we apply drill bit made of carbon steel, high-speed steel(HSS), and carbide. These three types of materials cover nearly all range of processed woods from hickory, beech to cedar, rosewood, and so on.
Carbon steel bits are only capable of dealing with wood in soft and medium hardness at low-speed processing velocity cause there is a clear working temperature limit for it, which is up to 250℃. Once the temperature rises higher than 200℃，carbon steel is tend to lose its ability to drilling. With more flexibility and resistance to brittle, especially, preferable hot-hardness, HSS retains 60HRC during 500℃, which makes it sufficient for drilling medium or even hardwood at medium fast feed milling inserts cutting speed. Topping HSS, Carbide stands up to 800℃ and remain the comparable drilling property. Prices on these three types of materials vary with their performance. Carbide drill bits’?performance is beyond doubt while they are enough costly.
However, if you just preferred a strong performer and expense is not your concern. Carbide and HSS are definitely sound choices to you. Besides they are relatively prevalent among all tool materials is their more superior affinity for chemical or physical coating. Endowed with this affinity, coated carbide and HSS tools are enhanced in aspects of hardness and self-lubricating.
Wisely Pick up Right Type of Drill Bits
You absolutely don’t want to use a traditional twist drill to trepan on a wooden surface cause their cutting edges are just way too wide and blunt, even though deep hole drilling inserts you have ground it. It seems like to slice a cake with a baseball stick. It could be done but the whole result could be in chaos. There are “special troops”?on the market to good purpose for your choice, Be aware of that.
Brad-point bit
Sharpening – a bit fiddly as it has to be done by hand. Sharpen the point and spurs with a fine file or edge of a fine grindstone; the angle between the point and spurs should be 90°
As a branch of twist drill bits, brad point bits are ideal for drilling holes mortised with dowels, and they have a structure like a trident in its transverse including a central point and 3 or 4 fringe corners(spurs) standing out the bits’?cutting edge. That’s why they are styled as spur bits and dowelling bits. These raised spurs not only prevent the drill bit sliding but also cut and remove excess wood fiber ahead of planing off the base of the hole by real cutting edges.
There is another kind of drill bits resembling brad point bits, which are called pilot bit. Both of them are able to cut more straight and cleaner hole than ones drilled by normal twist drill.
Spade bit
Spade bit for electric drilling only, the center point is in the position of the bit, and the flat steel on both sides cuts off the wood. These bits are used to drill fairly large holes. They provide a flat bottom hole (with a central point), so it is ideal where the head of the bolt/bolt needs to be embedded in wood – this bit must be used before drilling through the hole of the bolt.
Larger bits require fairly powerful bits to drill deep holes. Drill bits produce a lot of debris when they run out of the back of the workpiece – using sacrificial backplane or tape can reduce debris. Noteworthy spade bits are not suitable for enlarging existing holes.
Hole saw
This is a circular saw for cutting holes of large, fixed, diameter0 in wood. It’s usually cut to a depth of 18 mm or deeper. It is best used on low-speed power drills because the saw blade will cut through the whole board. In addition, there is a combination hole saw. Like the circular saws above, these combined saws can cut large holes, but they consist of many circular saws of different sizes, usually between 25 and 62 mm in diameter. Normally, the blade is fixed by a radial screw in the “head”. Before inserting a screw to fix the required diameter blade, all blades (except the required size) will be removed. It is best used on low-speed power drills cause the drill-through thing.
Auger bit
Auger bit is an ideal tool specialized for drilling large diameter and deep holes in wood or thick wood-based panels. Generally speaking, spiral drills can only be used on hand drills. The drill will cut clean, deep, flat-bottomed holes. A single straight tooth cuts and defines the edge of the hole, while a chisel cuts the edge to remove waste from the previous cutting circle. Hold the wood in the center of the thread and pull the drill into the wood. This “pull” action means that the bit is not suitable for use in electric drills.
Sharpening is also Important
As a skilled woodworker, knowing?how to sharpen drill bits before they get blunt will do yourself a good turn. Cause nearly every drill bit you get it home are not sharpened. Plus keep it in mind that ordinary fixed-handle bit can be reground three times and undercut bit can be reground two times. When the wear diameter is reduced by 2% compared with the original one due to wear, the bit will be discarded.
