Increase productivity with advanced milling

By OEM Update Editorial October 26, 2016 9:44 am

The innovations in tools can open up some machining alternatives which can boost the productivity. Rohan Ambike writes on how productivity can be increased through advanced milling.

In today’s fast paced environment, the sophisticated tooling and machining software give a chance to incorporate more products. In this process, most of the software has to integrate optimum tool feeds and speeds into those complex milling routines. Trial-and-error programming puts moulds, tools, machines and schedules at risk. Integrated tooling and software can get die and mould processes up and running quickly, without scrap. High Productive Milling (HPM) is a process of optimisation of the combination of high cutting speeds and feeds, up to a point of diminishing returns. The rationale is that higher output is only beneficial if the end result is good parts, minimum rework and near-zero scrap.

Milling pre-hardened dies and moulds to tighter tolerances generally slows down throughput of cutting tool feeds and speeds and lengthens machine cycle times. Demands for tighter tolerances and higher quality levels can lengthen machining times and slow production. Advanced milling tools are essential for mould makers to conquer hard materials, become more productive and stay in business. However, knowing what technology yields the greatest payoff and how to make the best of it takes the assistance of a knowledgeable tool supplier.

Speaking about the role of advancements in increasing the productivity for milling technology, Gautam Ahuja, Managing Director, Dormer Tools India Pvt Ltd says, “You also want to be sure you don’t get the output at the expense of early retirement of your expensive CNC centre due to excessive wear and tear. A lot depends on your application, work piece, component material, depth of cut, workload, and so on.”

“The latest milling cutters from Dormer Pramet are designed in such a way so as to use minimum spindle load. A positive geometry allows for a reduction in cutting forces, offering good productivity, lower machine power consumption and longer tool life. There are dedicated geometries of inserts to machine different types of materials. This helps in improved parameters, leading to increased productivity. The coatings on the inserts are available in both CVD and PVD, for maximum tool life. All cutters offer improved stability in a wide range of applications, even under unfavourable cutting conditions,” Ahuja adds.

Gautam claims that the company has Dormer Pramet cutters are robust in design with a positive geometry and dedicated insert geometries for each type of material, which are capable of taking high depths of cut, while at the same time work at high cutting speeds and feeds.

Highlighting the most recent developments of Dormer in the area of milling technology, Ahuja said, “S45OE is a completely new range of cutters and inserts for economical face milling of stainless steel form part of a launch of products by Pramet. The versatile range includes OEHT octagonal inserts for cutting depths 4 – 10 mm, alongside REHT (round) and XEHT (wiper) inserts.” He further says, “By utilising eight cutting edges, the highest number available for positive inserts – the new range provides an economical offer for customers, while the wiper insert option boosts feed rate capabilities and surface finish quality.”

Ahuja claims that Pramet’s Force AD range provides an ‘all-round’ milling option. The universal 90-degree cutter features Pramet’s ‘AD’ program of indexable inserts, including the ADMX07, ADMX11 and ADMX16. All offer improved stability in a wide range of applications, even under unfavourable cutting conditions.

CNC replaced conventional machines
CNC machines have replaced old conventional machines, because of their versatility and use. CNC machines are available for various applications for e.g. Milling, Grinding, Automation, hobbing, Die moulding etc. Its features are used for correction in process, accuracy of component produced etc.

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