with full 5-axis applications as most are long-running cutting operations with the cutter engaged in the material for long periods of time. Eventually the cutting tools wear, even in aluminum. Redundancy in the tools is key to keeping the spindle up and running. Having the same holder, cutter, etc. setup waiting in the tool magazine is best. It would then be called up automatically once a cutting tool’s life span has been met. The next best scenario is to have a cart of duplicate tools waiting next to the machine, but then the operator has to manually change the tool out. This may be a source of error, depending on the operator’s skill set. Using RFID chips on the holder, along with a tool management system, can aid in reducing the errors. Five-axis machining has unlocked creativity and productivity across the manufacturing world. It’s done the same for us and other suppliers of machining equipment. When preparing a new machine or process, don’t overlook how things like workholding and tooling have evolved to make this kind of work even more powerful.
Circle segment tools also come in multi-flute configurations. Add it all up and you get fewer tool passes while achieving better surface quality, faster feed rates, fewer tool changes and a more productive cutting process. Multi-Flute End Mills When it comes to 3 + 2 machining, more flutes on a cutting tool lets you maintain higher speeds and feeds simply because there are more edges in play. Moreover, the extra flutes provide more cutting surface on a given tool, which results in longer tool life. Altogether, these advantages result in much higher metal removal rates, better surface finish and lower overall cost. Tool Redundancy Redundancy is a risk management strategy that larger companies may employ for machines, tools and even employees. This becomes more important
Making coolant delivery as direct as possible is the key to providing proper heat dissipation, longer tool life, and better surface finish.
CONTRIBUTOR John Zaya is the Product Manager Workholding at BIG KAISER Email: firstname.lastname@example.org
How to Find Minimum Insertion Depth
TIPS & TRICKS
Q: I am trying to find the minimum insertion depth for cutting tools in holders. Other than referencing DIN, ISO or NAS standards for shank length to diameter dimensions, is there a rule used to determine the minimum insertion depth of an end mill, thread mill or drill bit into collets, shrink or hydraulic holders? A: The is no general rule to cutting tool shank insertion as a multiplier for shank diameter. All tool holder types have different requirements. The most important concept is that no matter what tool holder you are using, the cutting tool shank should be past the ground clamping section. An example of this is with ER32 collets. The smaller clamping sizes (Ø3mm) have an internal recess in the back of the collet. Even though the collet is 40mm long, the ground clamping length is only 19mm. As the clamping sizes get larger, the ground length increases (Ø12mm = 30mm) but is not relative to a set multiplier. Tool holders like shrink fit, hydraulic and milling chucks typically have the minimum insertion depth listed in catalogs. For holders like these, if the cutting tool shank does not pass through the ground portion of the holder, the bore can be damaged and ruin the entire chuck. Straight collets have the same type of recess. As long as the OD of the collet passes through the ground section of the holder, the cutting tool shanks can be shorter.
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