Optimising the process 1. Original solution Increasing cutting data with helix tools One of the general optimisation principles is to replace straight fluted tools with helix tool solutions. Combined with the C7 PLUS™ coating it is often possible to increase the cutting speed considerably while maintaining the same tool life time and machine wear. strategy Cast Iron demo 1 Page 1 of 1 Printed on 7. June 2006 at 14:29 Measuring File Path: Cycle: Date: Size: C:\Kistler\DynoWare\Data\Cast Iron demo\Cast iron demo 1.dwd 1 of 1 Wednesday, 07 June , 2006 13: 37: 50 238 876 Bytes Documentation Remark: Material: Tool: Straight flute drill vc = 130 m/min n = 4138 rpm f = 0,3 mm/rev vf = 1241 mm/min ap = 25 mm ae = -- mm Measuring Data Zoom on 2000 1800 1600 1400 1200 1000 800 600 400 200 0 1.0 -200 Fx [N] Cycle No.: 1 Fy [N] Cycle No.: 1 Fz [N] Cycle No.: 1 Mz [Nm] Cycle No.: 1 Cast Iron demo 1 Fx [N] Fy [N] Fz [N] Mz [Nm] 1.2 1.4 1.6 1.8 Time [s] Mean = -4.98 Mean = -2.99 Mean = 1820.94 Mean = 6.73 Min = -34.91 Min = -35.58 Min = 1692.02 Min = 4.19 2.0 2.2 Cycle No.: 1 Max = 26.31 Max = 24.78 Max = 1936.16 Max = 8.86 Integral = -5.04 Integral = -3.03 Integral = 1843.71 Integral = 6.82 Straight flute drill (C7 PLUS™ coated) 2. Replacing the straight flute drill with a twist drill Revealing the potential Measuring the thrust force of each solution when running at the same cutting parameters reveals the optimisation potential. Applying the same cutting parametres, the thrust force is much lower when using the twist drill than the straight fluted drill. However, the correct runnning in of the tools is a precondition for getting the optimum benefit of the improved tool solution. KISTLER DynoWare - Type 2825A1-2 2.4.0 n=4138 min -1 Feed 1241 mm/min Thrust force 1820 N Channel Label Sensitivity Units Range Units Filter [Hz] Time Const. Cast Iron demo 2 Page 1 of 1 Printed on 7. June 2006 at 14:31 Measuring File Path: Cycle: Date: Size: C:\Kistler\DynoWare\Data\Cast Iron demo\Cast iron demo 2.dwd 1 of 1 Wednesday, 07 June , 2006 13: 41: 53 238 876 Bytes Documentation Remark: Material: Tool: Twist drill vc = 130 m/min n = 4138 rpm f = 0,3 mm/rev vf = 1241 mm/min ap = 25 mm ae = -- mm Measuring Data Zoom on 1600 1400 1200 Cast Iron demo 2 Fx [N] Fy [N] Fz [N] Mz [Nm] 1000 800 600 400 200 0 -200 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0 Time [s] Cycle No.: 1 Fx [N] Cycle No.: 1 Fy [N] Cycle No.: 1 Fz [N] Cycle No.: 1 Mz [Nm] Cycle No.: 1 Mean = -2.24 Mean = -0.82 Mean = 1408.01 Mean = 5.64 Min = -37.78 Min = -47.97 Min = 1327.03 Min = 2.23 Max = 30.4 Max = 28.5 Max = 1493.65 Max = 8.33 Integral = -2.4 Integral = -0.88 Integral = 1510.09 Integral = 6.05 Increase the cutting data Increasing the cutting data The cutting parameters of the twist drill are increased until the thrust force is equivalent to the original straight fluted solution. The result is that the cutting data can be increased by up to 248% (Vf 3081 mm/min. / Vf 1241 mm/min.) Twist drill (C7 PLUS™ coated) KISTLER DynoWare - Type 2825A1-2 2.4.0 n=4138 min -1 Feed 1241 mm/min Thrust force 1408 N Channel Label Sensitivity Units Range Units Filter [Hz] Time Const. Cast Iron demo 3 Page 1 of 1 Printed on 7. June 2006 at 14:33 Measuring File Path: Cycle: Date: Size: C:\Kistler\DynoWare\Data\Cast Iron demo\Cast iron demo 3.dwd 1 of 1 Wednesday, 07 June , 2006 13: 44: 24 162 076 Bytes Documentation Remark: Material: Tool: Twist drill vc = 220 m/min n = 7003 rpm f = 0,44 mm/rev vf = 3081 mm/min ap = 25 mm ae = -- mm Measuring Data Zoom on 2000 1800 1600 1400 1200 1000 800 600 400 200 0 1.0 -200 Fx [N] Cycle No.: 1 Fy [N] Cycle No.: 1 Fz [N] Cycle No.: 1 Mz [Nm] Cycle No.: 1 Cast Iron demo 3 Fx [N] Fy [N] Fz [N] Mz [Nm] 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Time [s] Cycle No.: 1 Mean = -0.67 Mean = 0.89 Mean = 1791.56 Mean = 7.78 Min = -49.56 Min = -39.49 Min = 1699.71 Min = 4.46 Max = 52.25 Max = 49.5 Max = 1913.21 Max = 11.52 Integral = -0.26 Integral = 0.35 Integral = 698.71 Integral = 3.04 Contact us to learn more What would a similar optimisation do for your production capacity and unit costs? Contact your optimisation expert to learn more. Twist drill (C7 PLUS™ coated) n=7003 min -1 Feed 3081 mm/min Thrust force 1791 N Channel Label Sensitivity Units Range Units Filter [Hz] Time Const. KISTLER DynoWare - Type 2825A1-2 2.4.0 Even though the cutting parametres are increased by 248% the thrust force is now at the equivalent level of the original tool solution. (vf =3081 mm/min / vf =1241 mm/min = 2.48) Feed increased by 248% 6
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