Milling - Machining Elements for Productivity Analysis - News - Information for Industrial Engineering

News and Information to Facilitate Productivity Analysis of Machining Elements in Milling

Milling Machines and Operations

Milling Operations
 Peripheral Milling
 Face Milling
 Milling Cutters

General-Purpose Milling Machines
  Knee-Type Milling Machines
 Vertical Bed-Type Milling Machines
 Planer-Type Milling Machine
 Rotary-Table Milling Machines


 Holding Cutters and Workpieces on Milling Machines

 Cutter Mounting

 Workpiece Fixturing

 Dividing Heads
 Universal Dividing Heads
 Modes of Indexing

Basic Information on Milling

Milling machines are employed for machining flat surfaces, contoured surfaces, complex and
irregular areas, slotting, threading, gear cutting, production of helical flutes, twist drills, and spline
shafts to close tolerances.

Peripheral Milling
In peripheral milling, the cutting occurs by the teeth arranged on the periphery of the milling cutter,
and the generated surface is a plane parallel to the cutter axis. Peripheral milling is usually performed on a horizontal milling machine. For this reason, it is sometimes called horizontal milling.

Up-Milling (Conventional Milling)
Up-milling is accomplished by rotating the cutter against the direction of the feed of the WP

Down-Milling (Climb Milling)
Down-milling is accomplished by rotating the cutter in the direction of the work feed,

Advantages of down-milling include the following:
Fixtures are simpler and less costly, as cutting forces are acting downward.
Flat WPs or plates that cannot be firmly held can be machined by down-milling.
Cutter with higher rake angles can be used, which decreases the power requirements.
Tool blunting is less likely.
Down-milling is characterized by fewer tendencies of chattering and vibration, which leads
to improved surface finish.

In face milling, the generated surface is at a right angle to the cutter axis.
Face  milling is usually performed on vertical milling machines; for this reason, the process is called vertical milling, which is more productive than plain milling.

Milling Cutters

1. Plain milling cutters are either straight or helical ones. Helical milling cutters are preferred for large cutting widths to provide smooth cutting and improved surface quality.  Plain milling cutters are mainly used on horizontal milling machines.
 2. Face milling cutters are used for the production of horizontal, vertical , or inclined flat surfaces. They are used on vertical milling machines, planer type milling machines, and vertical milling machines with the spindle swiveled to the required angle α, respectively.
 3. Side milling cutters are clamped on the arbor of the horizontal milling machine and are
used for machining of the vertical surface of a shoulder or cutting a keyway
 4. Interlocking (staggered) side mills  mounted on the arbor of the horizontal
milling machines are intended to cut wide keyways and cavities.
 5. Slitting saws  are used on horizontal milling machines.
 6. Angle milling cutters, used on horizontal milling machines, for the production of longitu dinal grooves  or for edge chamfering.
 7. End mills are tools of a shank type, which can be mounted on vertical milling machines (or
directly in the spindle nose of horizontal milling machines). End mills may be employed in
machining keyways  or vertical surfaces.
 8. Key-cutters are also of the shank type that can be used on vertical milling machines. They
may be used for single-pass milling or multipass milling operations.
 9. Form-milling cutters are mounted on horizontal milling machines. Form cutters may be
either concave or convex.
10. T-slot cutters are used for milling T-slots and are available in different sizes. The T-slot is
machined on a vertical milling machine in two steps:
Slotting with end mill
Cutting with T-slot cutter
11. Compound milling cutters are mainly used to produce compound surfaces. These cutters
realize high productivity and accuracy .
12. Inserted tool milling cutters have a main body that is fabricated from tough and less expensive steel. The teeth are made of alloy tool steel, HSS, carbides, ceramics, or cubic
boron nitride (CBN) and mechanically attached to the body using set screws and in some
cases are brazed. Cutters of this type are confined usually to large-diameter face milling
cutters or horizontal milling cutters.
13. Gear milling cutters are used for the production of spur and helical gears on vertical or
horizontal milling machines. Gear cutters are form-relieved cutters, which are used to mill contoured surfaces. They are sharpened at the tooth face.

Hobbing machines and gear shapers are used to cut gears for mass production and high accuracy demands.

DIVIDING HEADS

Dividing heads are attachments that extend the capabilities of the milling machines. They are mainly employed on knee-type milling machines to enhance their capabilities toward milling straight and helical flutes, slots, grooves, and gashes whose features are equally spaced about the circumference of a blank (and less frequently unequally spaced). Such jobs include milling of spur and helical gears, spline shafts, twist drills, reamers, milling cutters, and others. Therefore, dividing heads are capable of indexing the WP through predetermined angles. In addition to the indexing operation, the dividing head continuously rotates the WP, which is set at the required helix angle during milling of helical slots and helical gears. There are several versions of dividing heads:

Plain dividing heads are mainly used for indexing milling fixtures.

Universal dividing heads.

Optical dividing heads are commonly used for precise indexing, and also for checking the
accuracy of marking graduation lines on dial scales.

Detailed Basic Information in 21st Century Manufacturing: National Initiative For Product Data Exchange: Product Data Exchange Baseline Activity
DIANE Publishing Company
30-Aug-2004  430 pages
https://books.google.co.in/books?id=6PE0jZZ-nr0C&pg=PA332#v=onepage&q&f=false
https://books.google.co.in/books?id=6PE0jZZ-nr0C

Basics: Cutting Tool Applications Chapter 13: Milling Methods & Machines

George Schneider
OCT 27, 2010
https://www.americanmachinist.com/machining-cutting/article/21891846/cutting-tool-applications-chapter-13-milling-methods-machines


Face milling
https://www.sandvik.coromant.com/en-gb/knowledge/milling/pages/face-milling.aspx

Force, Torque, and Power
Calculate Tangential Force, Toque, and Machining Power for Face Milling Applications.
https://www.kennametal.com/in/en/resources/engineering-calculators/face-milling-calculators/force--torque--and-power.html

Tech Tip: 45° vs 90° Face Milling
Advantages and Disadvantages of Using a 45-degree Face Mill vs. a 90-degree Face Mill
To achieve greater productivity and problem-free milling, use a lead angle cutter whenever possible. Chip thickness is affected by the lead angle. The greater the lead angle, the greater the chip-thinning effect.
https://www.kennametal.com/in/en/resources/technical-tips/milling/tech-tip--124---45--vs-90--face-milling.html

News and Information of Machining Elements in Milling

1981

Chapter 14 Production Milling in
Production Processes: The Productivity Handbook
Roger William Bolz
Industrial Press Inc., 1981 - Technology & Engineering - 1089 pages
Reviews all the latest developments and refinements, including their design details, materials, practical tolerances, and working finishes.  Allows the reader to objectively evaluate and compare different processes and equipment with their inherent advantages for any particular
https://books.google.co.in/books?id=C4SUXiL7gB0C&pg=SA14-PA1#v=onepage&q&f=false
Book preview link: https://books.google.co.in/books?id=C4SUXiL7gB0C

1999

10/15/1999 | 9 MINUTE READ
Tooling Tips For High Productivity Milling
Today's machining centers feature higher spindle speeds and feed rates, but if you want to push this capability to the limit, there are some tooling considerations that must be addressed.
https://www.mmsonline.com/articles/tooling-tips-for-high-productivity-milling

Speed Up, Slow Down For High Productivity
OPTIMIZING FEEDRATES ACCORDING TO THE AMOUNT OF MATERIAL TO BE CUT MINIMIZES MACHINING TIME WHILE PROTECTING CUTTERS.
James Benes
MAY 08, 2006
https://www.americanmachinist.com/machining-cutting/article/21893779/speed-up-slow-down-for-high-productivity

2007

Introducing Crankshaft Miller Model GPM170F-5 

Komatsu Tech-innovation
PDF
The crankshaft miller, a leading product of the machine tool business of Komatsu Machinery Corporation, has been model-changed targeting “Improved working environment,” “Energy saving,” “Enhanced flexibility” and “Enhanced productivity.” The new miller was introduced into the market in 2007. The background, technologies and features of the new product are described.
https://home.komatsu/en/company/tech-innovation/report/pdf/159-08_E.pdf

Patent: Milling cutter for the milling of exotic materials such as titanium alloys, stainless steel, nimonic alloys etc.

Milling cutter manufacturing method
With Rolls Royce

This invention relates to a method of manufacturing a milling cutter for the milling of so-called exotic materials such as titanium alloys, stainless steel, nimonic alloys etc, which are notoriously difficult to machine.

A method of manufacturing a milling cutter in accordance with the preamble of claim 1 is known from HELLE H.J. "NEUE TECHNIK ZUM SCHLEIFEN VON GESENKFRÄSERN", WERKSTATTSTECHNIK, SPRINGER VERLAG, BERLIN, vol. 79, no. 3, 01/03/1989, pages 153-157.

The aerospace industry makes extensive use of titanium alloys etc, and, in common with other industries, continually seek to reduce costs of manufacture through through either outsourcing to cheaper economies or increasing production.
https://patents.google.com/patent/EP2121243B1/en

2008

KSCM AluMill face-milling system from Kennametal for high-productivity 

With a steel and aluminum body construction that offers reduced weight, improved rigidity and vibration-dampening characteristics, the KSCM AluMill face-milling system from Kennametal is designed to achieve high speeds and high-productivity results, especially for high-volume aluminum milling operations.
January 30, 2008
In particular, automotive applications such as engine blocks and cylinder heads can benefit from the KSCM AluMill system’s design and performance. KSCM AluMill cutters are available between 2.5 in. and 12 in. diameters
https://www.canadianmetalworking.com/canadianmetalworking/product/cuttingtools/face-milling-system-offers-improved-rigidity

2010

Performance Improvement of the Mitsubishi Heavy Industries  Vertical Precision Milling Machine
MVR Allows High-Accuracy Processing of Automotive Molds and
High-Efficiency Production of Large Molds to be Realized
Mitsubishi Heavy Industries Technical Review Vol. 47 No. 4 (December 2010)
https://home.komatsu/en/company/tech-innovation/report/pdf/159-08_E.pdf

2011

High-density work-holding can squeeze more productivity from your machining center
Kip Hanson
Published September 1, 2011
https://www.ctemag.com/news/articles/high-density-workholding-can-squeeze-more-productivity-your-machining-center

2016

The SORALUCE SLP fixed table travelling column machine

The SORALUCE SLP fixed table travelling column machine is a large capacity machine designed in a compact and ergonomic format, offering great flexibility. The machine offers high precision finishing results, based on a unique traditional machine architecture: table attached column
supported by a separate rear guide, to improve machine stability, whilst maintaining its very low centre of gravity. It is the ideal machine for several applications in different sectors such as industrial vehicles, moulds and dies, capital goods and medium sized precision engineering components, ensuring highest precisions and efficiency results.
https://www.danobatgroup.com/media/uploads/prensa/soraluce-slp-fixed-table-travelling-column-milling-centre.pdf

Patent for an Improved Shell End Mill

Inventor Berend Denkena, Dennis Nespor
Current Assignee Leibniz Universitaet Hannover

In milling, productivity is a crucial issue. This is especially true for roughing, with a large chip removal rate. Here, to achieve as far as possible in the shortest possible processing time of the final contour by coarse-toothed tools ,  large depth of cuts are applied, so that a large chip volume is created. Roughing processes are used in particular in the production of integral components of titanium alloys and aluminum alloys for the aerospace industry.

Shell end mills with indexable inserts have the advantage that damaged and / or worn indexable inserts can be replaced individually. The exchangeable indexable inserts can be arranged spirally next to each other on the tool body, so that the adjacent indexable inserts can each jointly form a cutting edge. Shell end mills can achieve high productivity and process reliability, e.g. titanium alloys as well as other difficult-to-machine materials or steel alloys and aluminum alloys.

The present invention relates to a milling tool, in particular a shell end mill, with at least two indexable inserts, wherein the two indexable inserts  in the longitudinal direction (y) of the shell end mill  are offset from each other in such a way that they overlap one another in an overlapping region  by an overlap (t), and wherein the two indexable inserts  are offset in the circumferential direction (U) of the shell end mill  in such a way that their cutting edges  form a resulting cutting edge  of the shell end mill. The milling tool  is characterized in that at least one cutting edge  of at least one indexable insert, preferably both indexable inserts, at least in sections has a contour, so that at least partially a not-just resulting cutting edge. of the milling tool yields.
https://patents.google.com/patent/DE102016104005A1/en

Analyzing the Effect of Machining Parameters Setting to the Surface Roughness during End Milling of CFRP-Aluminium Composite Laminates
M. Nurhaniza, M. K. A. M. Ariffin, F. Mustapha, and B. T. H. T. Baharudin
Research Article | Open Access
International Journal of Manufacturing Engineering
Volume 2016 |Article ID 4680380

The machining parameters involved in this experiment are cutting speed, feed rate, and depth of cut. The main objective is to find the combination of machining parameters to achieve low surface roughness during end milling.

The workpiece materials is made by the combination of carbon fiber reinforced polymer (CFRP) and aluminium alloy 2024-T3. In this experiment, the selected cutting tool is polycrystalline diamond (PCD) end mill with 6 mm diameter and 0.2 mm corner radius.

The factor level used are:


                                                  Factor Level
                                                   1             2            3
A: spindle speed (RPM)  3000 4000 5000
B: feed rate (mm/min)           800 1200 1600
C: depth of cut (mm)          0.2         0.3         0.375

The highest value of surface roughness is found when the feed rate = 1600 mm/min and spindle speed = 3000 rpm. Generally, the combination of high spindle speed and low feed rate produces better surface finish, supported by previous findings of others.
https://www.hindawi.com/journals/ijme/2016/4680380/

TVS MOTOR Co. Ltd
September 20, 2016Abhishek D20150 Comments
Title of case study:
Productivity improvement and flow manufacturing in machining fixtures and gauges through innovation and design standardization.
https://productivity.imtma.in/tvs-motor-co-ltd/

High-speed hard milling tips for successful mold production
May 25, 2016
https://mfgtechupdate.com/2016/05/high-speed-hard-milling-tips-for-successful-mold-production/

2017

HOW TO MAXIMIZE MACHINE PRODUCTIVITY: CHIP THINNING
Kip Hanson
Chip thinning is often radial in nature, but can be axial for face milling.
Trochoidal toolpaths allow for lighter radial cuts at higher feed rates and longer axial engagement, thus reducing cutting forces and improving tool life.
Newer, high-performance end mills, harder carbide, chip evacuation and firmer grips—and other tips and tricks, are all part of the new programming paradigm for maximizing machine productivity.
https://www.mscdirect.com/betterMRO/metalworking/how-maximize-machine-productivity-chip-thinning


MILLING TECHNIQUES TO IMPROVE METAL REMOVAL RATE

Introduction of inserts made of KCSM40 for Millinh Ti-6Al-4V
Users of inserts made of KCSM40 are now machining Ti-6Al-4V at 160 surface feet per minute when they might have reached only 140 SFM in the past.

A 4-inch diameter cutter  could have 8, 12 or 15 teeth. A 15-tooth cutter of that size considered very high density. If you use a 15-tooth cutter, you’re improving your productivity because you’ll have more teeth in the cut.  But you have to make sure that  spindle can take the load by doing  cutting-force calculations and  use the appropriate  highest-density cutter.

Owners of rigid machines equipped with a low-speed spindle can use a “helical” cutter such as Kennametal’s new Harvi Ultra 8X, which is designed to offer longer tool life than traditional cutters at high MMR

Designed to mill grooves up to 6 millimeters wide, the CoroMill QD cutter from Sandvik Coromant, of Fair Lawn, New Jersey, uses geometry and a novel coolant delivery system to solve chip-related problems. The QD’s insert geometry produces chips that are thinner than the groove being machined. These chips are flushed out by coolant delivered through the cutter body to each cutting edge. Besides boosting MRR, this system dramatically increases tool life and the surface quality of milled components.
https://www.mscdirect.com/betterMRO/metalworking/milling-techniques-improve-metal-removal-rate

Heady Times for High-Feed Milling
August 21, 2017
New technology boosts a tried and true process
https://www.sme.org/technologies/articles/2017/august/heady-times-high-feed-milling/

2018

2018
Square shoulder milling endmills with small diameter with exceptional stability and productivity
https://www.tungaloy.com/wp-content/uploads/506.pdf

Milling Faster than Eroding
Modern Milling Technology Improves the Production of Die-Cast Parts
16.07.2018 | Author/ Editor: Klaus Vollrath / Alexander Stark
https://www.spotlightmetal.com/modern-milling-technology-improves-the-production-of-die-cast-parts-a-733750/

Pocket NC V2  Mill Improvements
Summer 2018 Update by Pocket NC August 17, 2018

We chose to switch to using a THK Cross-Roller Ring bearing. This bearing offers the ability to carry a load in all directions: axial, radial and moment loads are supported. The V2 now achieves a higher level of rigidity in the rotary axes of the machine without increasing the exterior dimensions of the Pocket NC.  The rigidity of the of the rotary axes was improved by a factor of 2 and the run out of the rotary axes was decreased by a factor of 4, the strength/force of the rotary axes movement is about double what is was before due to less friction in the bearing. All this adds up to a more rigid machine which results in improved machining performance in material removal rate and surface finish.

We discovered that our calibration of the rotary axes on the machine was a weak link in our system. Our system relied on checking only two points, the home position and one other point in the rotation.
We developed some new fixtures that allowed us to check 8 points rather than 2. This revealed that there could be errors of up to 0.5° at points in between the two points that we previously checked.
We ultimately determined that it was due to some inconsistencies in the manufacturing of the gears that we build in-house. We made some changes to our manufacturing process and were able to correct about 50% of the error, down to a max error of about 0.25°. We continued with our manual measurements at 8 points and added rotary axis compensation at 4 points in the travel of both A and B. This resulted in another decreased rotary position error of about 50% down to about 0.12°. Enter the Renishaw probe. Our software and hardware team have been working closely together on developing a solution that delivers consistent, accurate results.   We are now able to compensate the rotation of the A and B axes with enough precision to reach rotational accuracy of 0.05° at every angle.

Price
Which leads us to price, after careful consideration we’ve decided to implement a price increase starting September 1, 2018.The new price of the V2 will be $5500.
https://pocketnc.com/blogs/updates/2018-8-16-pocket-nc-v2-summer-2018-update

2019

Effects of Machining - Milling Parameters on the Quality in Machining of Aluminium Alloys Thin Plates
Published: 24 August 2019, Metals
https://www.mdpi.com/2075-4701/9/9/927/pdf


Automated Fixture Creation for CNC Milling Using a Generative Design Approach
https://www.autodesk.com/autodesk-university/class/Automated-Fixture-Creation-CNC-Milling-Using-Generative-Design-Approach-2019#downloads

Productivity Increase – Model-based optimisation of NC-controlled milling processes to reduce machining time and improve process quality
C.Brecher⁎ M.Wiesch⁎ F.Wellmann⁎
IFAC-Papers OnLine
Volume 52, Issue 13, 2019, Pages 1803-1807
https://www.sciencedirect.com/science/article/pii/S2405896319314442

Multi-Response Optimization of Face Milling Performance Considering Tool Path Strategies in Machining of Al-2024
Ali, Raneen Abd et al. “Multi-Response Optimization of Face Milling Performance Considering Tool Path Strategies in Machining of Al-2024.” Materials (Basel, Switzerland) vol. 12,7 1013. 27 Mar. 2019, doi:10.3390/ma12071013
https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6479395/

Multi Objective Optimization in CNC End Milling of Inconel 718 Super Alloy by Taguchi-Grey-Fuzzy Method
2019 International Conference on Nascent Technologies in Engineering (ICNTE)
https://ieeexplore.ieee.org/document/8945898

Faster and better machining performance: on existing equipment
04 May, 2019
Unleashing the hidden potential of existing equipment with BIG-PLUS® spindles
https://www.cnctimes.com/editorial/faster-and-better-machining-performance-on-existing-equipment

Integrated optimization of cutting tool and cutting parameters in face milling for minimizing energy footprint and production time
Xingzheng  Chen,   Congbo Li,  Ying Tang,  Li Li, Yanbin Du, Lingling Li
Energy
Volume 175, 15 May 2019, Pages 1021-1037
https://www.sciencedirect.com/science/article/abs/pii/S0360544219303561

Optimisation of Cutting Tool and Cutting Parameters in Face Milling of Custom 450 through the Taguchi Method
Research Article | Open Access
Advances in Materials Sciene and Engineering
Volume 2019 |Article ID 5868132 | 10 pages
https://www.hindawi.com/journals/amse/2019/5868132/



https://community.sw.siemens.com/s/article/a-practical-approach-to-identify-feeds-and-speeds-settings-for-peak-and-stable-high-speed-machining-performance

https://www.canadianmetalworking.com/canadianmetalworking/article/cuttingtools/a-look-at-high-speed-machining

https://amtil.com.au/face-milling-with-ceramic-cutting-tool-materials-for-nickel-based-alloys/

Boosting Shop Productivity by Applying High Efficiency Milling Techniques
22 Dec 2019
Autodesk Fusion 360
______________

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Precise Measurements in a turning-milling Machining Centre

03/28/2019 - Measuring Components
Production Metrology from BLUM at Tries

Most of the milling machines at Tries are equipped with LaserControl measuring systems from BLUM. Laser measuring systems are indispensable in production, and the tool is measured after each machining operation to detect any tool breakage. The portfolio of various touch probes and laser measuring systems is further enhanced with two Z-Nano tool setting probes that are used on a Matec machining centre with two tables. This allows machining on one table and the clamping and unclamping of workpieces on the other. The Z-Nano also permits very high probing speeds in order to keep measuring times as short as possible.
https://www.blum-novotest.com/en/news/news-stories/detail/news/precise-measurements-in-a-turning-milling-machining-centre.html

Productive aluminium milling for automotive powertrains
2019-03-28


Sandvik Coromant offers a well-rounded selection of milling cutters for aluminium automotive components.
M5Q90 is the cubing specialist of the M5 family of milling concepts, in other words it is designed for the first roughing stage to clean the surfaces of newly cast parts. These shoulder cutter with indexable inserts have cutting edges only on the radial periphery of the tool body. M5R90 is a roughing and semi-finishing concept for shoulder milling operations, with cutter diameters ranging between 63 and 250 mm (2.48–84 inch). The tool has re-grindable PCD tips brazed to a steel cartridge, which allows axial adjustments and consequently large depths of cut, up to 8 mm (0.315 inch). Two radius options, 0.4 mm and 0.8 mm (0.016 / 0.031 inch), are available, depending on the cartridge model. M5R90 is a reliable, easy-to-use cutter that can be optimally teamed up with M5B90 when excellent surface finishes are required (below 4Rz).
https://www.sandvik.coromant.com/en-gb/mww/pages/t_crankshaft.aspx

April 2019
10 Useful Tips for Titanium Milling
https://www.mcctcarbide.com/es/10-useful-tips-for-titanium-milling/

May 2019
The Lightweight CoroMill 390 can perform long-reach face milling, deep shoulder and side milling, cavity milling, and slot milling. The tool is available in 40 mm and 50 mm diameter variants.
https://3dprintingindustry.com/news/sandvik-coromant-introduces-new-3d-printed-metal-cutting-tool-to-improve-productivity-154451/

Face milling cutter combines productivity with cost-effectiveness
11 JUNE 2019
Walter GB says the new M2127 PCD face milling cutter is a logical continuation of the company’s M4000 system concept.

Users can reduce costs by utilising a universal system of inserts for different tools and differing applications for aluminium machining.

Designed for high-speed applications, the cutter is available in diameters up to 250mm and is ideal for both roughing and finishing aluminium as well as for smear milling and for finishing bi-metal components.
https://www.aero-mag.com/walter-gb-m2127-pcd-face-milling-cutter/

July 2019

The first fully automatic milling machine for aluminium ingots
Highly automated system cuts machining-cycle times by more than 30 percent.

Kreuztal, Germany, 29 July 2019 GEORG will be unveiling its new ultramill series of portal-type milling machines for milling of aluminium ingots at the 2019 Aluminum USA. It machines all surfaces, including the end and side faces, in just two clamping cycles. A high level of automation and a high machining speed achieve a significant increase in system throughput compared to machines customary up to now.
https://www.georg.com/en/press/press-release/news/the-first-fully-automatic-milling-machine-for-aluminium-ingots-1/


November 2019
KOR 5 from Kennametal for Productivity in  aluminum roughing for aerospace

Kennametal announced its latest innovation in high-velocity aluminum roughing, the KOR 5 solid carbide end mill. Designed for maximum productivity in aerospace machining, with this five-flute end mill table feed rates increase up to 66 percent compared to commonly used three-flute tools—redefining productivity for aircraft manufacturers and their suppliers.
https://blog.wor-con.com/new-kor-5-solid-carbide-end-mills-offer-maximum-productivity/?lang=en

December 2019
Tungaloy’s DoForce-Tri 07 insert maximizes shoulder milling productivity

Tungaloy expands its DoForce-Tri line of square shoulder milling cutters to include a size 07 insert, with 6 cutting edges for precision milling and insert economy.
https://www.canadianmetalworking.com/canadianmetalworking/product/cuttingtools/tungaloys-doforce-tri-07-insert-maximizes-shoulder-milling-productivity

DoForce-Tri 07 - High productive and cost-effective shoulder milling cutter with 07 size insert
1 Jul 2019
TungaloyCorporation
______________

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Tungaloy’s New TungEight-Mill Light Cutting Face Mill Increases Productivity in Low HP Machines
16. Dec. 2019.
Iwaki, December 2019 — Tungaloy unveils TungEight-Mill face milling cutter for extremely light cutting with low power consumption.

TungEight-Mill incorporates single-sided positive inserts with economical 8 cutting edges for heavy roughing to mirror finishing of various material faces. The cutter is designed to provide light cutting action suitable for weak fixtures and low horsepower machines with a BT-30 connection. A high positive rake angle of the insert and its optimal orientation on the cutter contributes to forming a helical shaped chip, allowing smooth chip evacuation and application security. The feature is particularly effective when machining low carbon steel and stainless steel with chip breaking difficulty and tendency to smear.
https://www.tungaloy.com/press-release/new_tungeight-mill/

2020

Taking Stainless Steel Machining to the Next Level
January 3, 2020
Tips for choosing cutting tools, toolpaths and machines wisely
https://www.sme.org/technologies/articles/2019/december/taking-stainless-steel-machining-to-the-next-level/

JWD Machine Inc. of Fife, Wash.
The company has been recognized as a Boeing Supplier of the Year award winner, and it is known by others outside of the aerospace manufacturing industry for its development of the widely used Techni-Grip™ fixturing system. With its long and growing list of accomplishments, JWD understands that it has a reputation to uphold in the face of relentless competition, which is why the company embraces and leads with high-performance machining technology.
https://www.radical-departures.net/articles/titanium-milling-automation-productivity-soar-at-jwd/


Thread milling achieves high productivity in certain applications.
March 2020
Thread milling should always be the application of choice when:

Machining asymmetric/non-rotating components
Machining materials that cause chip breaking and chip evacuation problems
Machining tough materials that create high cutting forces
Machining against a shoulder or close to the bottom of a blind hole
Machining thin-walled components
Component set-ups are unstable
Tool inventory needs to be minimized
You do not want to risk tap breakage on expensive parts – thread mills can always be removed from the component completely
A machine tool capable of simultaneous movement in the X, Y and Z-axis directions is required

https://www.sandvik.coromant.com/en-gb/knowledge/threading/thread-milling/pages/default.aspx


Physics-Guided Machine Learning for Increased Milling Productivity
SMART MANUFACTURING/INDUSTRY 4.0
March 18, 2020  2:35 pm - 3:00 pm
This presentation will describe the application of artificial intelligence (AI) to precision part machining. Specifically, it will summarize current efforts toward autonomous operation, or the ability of a machine to understand its current state and respond accordingly. The innovation is the combination of machine learning and physics-based models to provide hybrid physics-guided machine learning (PGML) approaches that improve the accuracy, physical consistency, traceability, and generalizability of model predictions. This disruptive capability is poised to redefine manufacturing from the machine tool to the enterprise across the global economy. The research efforts leverage current activities in AI, machining process modeling, and in-process sensing. The approach is to use experimental capabilities to generate data, define physics-based process models, couple the data and physics-based models with machine learning algorithms in new hybrid modeling approaches, and test the subsequent operating parameter predictions.

Learning Objectives:

Understand machine learning algorithms available for manufacturing modeling
Understand machining process models that can be used for performance prediction
Understand how physics-based and machine learning models can be combined to improve milling productivity

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Tony Schmitz, PhD
Professor/ORNL Joint Faculty
University of Tennessee, Knoxville
https://www.aerodefevent.com/sessions/physics-guided-machine-learning-for-increased-milling-productivity/

COMPACT MILLING MACHINE ENDURA® 700LINEAR
The ENDURA® 700LINEAR is a state-of-the-art 5-axis milling machine in compact portal construction with linear motor drive technology and 5 CNC-controlled simultaneous axes. This machine tool is especially suited for the rational finish-machining from 5 sides of work pieces made of plastics, composite materials (carbon fibre reinforced plastic, glass fibre reinforced plastic), model making block material (ureol) and aluminium, as well as HSC-machining of cast iron and steel materials.

The compact 5-axis milling machine ENDURA® 700LINEAR features a high structural rigidity, is extremely dynamic and reaches tight accuracies. These characteristics result in an optimal motion control and the maximum possible productivity. Despite its compact contruction and small installation surface, the 5-axis milling machine offers a large machining space. Futhermore, this machine tool does not require a foundation.  With an acceleration of up to 3.5 m/sec², the FOOKE ENDURA® 700LINEAR is one of the latest high speed milling machines.

https://www.fooke-portalfraesmaschinen.de/en_US/milling-machines/compact-milling-machine-endura-700linear.html

Development of a form milling method for line gear: principle, CNC machine, cutter, and testing. 

Int J Adv Manuf Technol (2020).  Chen, Y., Hu, Y., Lyu, Y. et al.  https://doi.org/10.1007/s00170-019-04771-2

Relevant method of form milling for line gear, a new type of gear, was studied in this paper. Firstly, the principle of a form milling for line gear was presented
https://link.springer.com/article/10.1007/s00170-019-04771-2

7/6/2020 

Optimized roughing, also called high-efficiency milling -Rough Faster With Better Tool Life in Difficult Materials

Optimized roughing, also called high-efficiency milling, is an effective way to improve material removal rates and tool life for titanium and hard-to-machine alloys, but knowing when to use it is as important as knowing how.

https://www.mmsonline.com/articles/rough-faster-with-better-tool-life-in-difficult-materials

Milling dynamic model based on rotatory Euler–Bernoulli beam model under distributed load
Qi Yao,    Ming Luo,   Dinghua Zhang
Applied Mathematical Modelling
Volume 83, July 2020, Pages 266-283
Highlights
•Cutter-holder-spindle dynamic system is simplified considering milling conditions.
•A rotatory Euler–Bernoulli beam model is used on cutter vibration modeling.
•Cutting force fluctuation is involved with cutter vibration synthesized.
https://www.sciencedirect.com/science/article/abs/pii/S0307904X20301001


Quality Retention Knobs for Toolholders

Ohio-based T.J. Davies, a manufacturer of high-quality retention knobs  utilizes certified 86L20 and 9310 steel drawn in the United States providing  retention knobs with high reliability at higher RPMs during CNC machining.

86L20, a low alloy nickel, chromium, molybdenum case hardening steel, has high hardenability without temper brittleness, along with good external and internal strength, and high wear-resistance.  9310, a low alloy steel composed mostly of nickel and chromiumis still higher quality steel.  This alloy also has high hardenability, core hardness and fatigue strength, which makes it an excellent steel for use in heavy-duty machinery.

Long-term reliability also depends on utilizing a superior coating to prevent corrosion.  Each retention knob is coated with black oxide by Davies.  It prevents rust, increases abrasion resistance while providing a decorative finish.
https://www.ctemag.com/news/industry-news/high-quality-retention-knobs-increase-cnc-productivity

(Need to add more information from April to June 2020 on milling machine productivity.

August 2020

https://www.automation.com/en-us/articles/august-2020/universal-machine-increases-job-shop-productivity

https://www.pesmedia.com/hurco-live-tooling-24082020/

https://www.mmsonline.com/articles/no-need-for-speed

https://www.a-star.edu.sg/simtech/kto/modular-programmes/dynamics-analysis-and-simulation

https://www.americanmachinist.com/cutting-tools/article/21898326/next-wave-end-mills-increase-productivity

https://www.americanmachinist.com/enterprise-data/article/21898520/mes-increases-machine-availability-for-mazak

September 2020

Kennametal Tools  Innovations 2021-01

https://www.kennametal.com/us/en/products/featured-products.html

A stunning machine for World class machining

https://mtdcnc.com/news/dts-uk-ltd/a-stunning-machine-for-world-class-machining

Jergens Pyramid Risers Provide A New Angle For Multi-Part, Five Axis Machining Productivity

By Industrial Machinery Digest -September 3, 2020

https://industrialmachinerydigest.com/industrial-news/product-news/jergens-pyramid-risers-provide-a-new-angle-for-multi-part-five-axis-machining-productivity/

Speed up your Milling with Constant Cutter Forces

Ellie Rathbone, September 3, 2020

WHAT YOU DON’T KNOW ABOUT HIGH EFFICIENCY ROUGHING VS HIGH SPEED ROUGHING IS COSTING YOU MONEY

https://blogs.autodesk.com/advanced-manufacturing/2020/09/03/speed-up-your-milling-with-constant-cutter-forces/

The CNC horizontal machining center benefits

Posted on Sep 4, 2020

https://www.imts-exhibition.com/blog/the-cnc-horizontal-machining-center-benefits.html

Theos 98 SL - mobile column milling machine

Theos 98 SL is equipped with a table, with double pinion and backlash elimination system, which allows 5 axis machining tasks. Added to its high feed rates (up to 40 m/min), this results in an outstanding productivity.

https://juaristi.com/news/theunstoppable-floor-type-milling-machine-ml-series-spanish-subcontractor/

Vibration-free machining in difficult conditions

Walter presents vibration-damping Accure·tec technology

https://www.manufacturingtodayindia.com/products-suppliers/8319-vibration-free-machining-in-difficult-conditions

Hole Machining Operations & G-Code | How to Machine/Cut a Hole on Milling Machines | CNCLATHING

2020.9.11

https://www.cnclathing.com/guide/hole-machining-operations-g-code-how-to-machine-cut-a-hole-on-milling-machines-cnclathing

2021

Online adaption of milling parameters for a stable and productive process

Benjamin Bergmann, Svenja Reimer.

CIRP Annals

Volume 70, Issue 1, 2021, Pages 341-344

In  fully autonomous machine tools,  it is essential to independently select suitable process parameters and adapt them on-the-fly to the appropriate process conditions in a self-controlled manner.  This paper introduces a new approach enabling machines during the milling process to learn which parameters lead to a stable process with maximum productivity and to adjust them autonomously. This approach enables the machine tool to independently find stable process parameters with maximum productivity.

https://www.sciencedirect.com/science/article/pii/S0007850621001104

CAN YOU IMPROVE MATERIAL REMOVAL RATE WHILE INCREASING TOOL LIFE, MINIMIZING TOOL WEAR, AND MAINTAINING PROCESS SECURITY?

The short answer is yes.

HOW IS THIS POSSIBLE?

Where component and set up fit, Dynamic milling (DM, also known as optimized or advanced roughing) is the answer.

https://www.secotools.com/article/119125?language=en

Walter presents the Xtra tec® XT M5009 and M5012 Face Milling Cutters for Increased Productivity.

The M5009 and 5012 face milling cutters are of  12 mm insert size.  With an approach angle of 45° and thanks to its higher number of teeth, the M5009 (diameter 25–160 mm) is ideal for  increasing  productivity in mass production. The M5012 (diameter 32–160 mm) has a steep approach angle of 88°, making it possible to work with larger machining conditions and depths of cut (8 or 10 mm) and is less affected by interference contours. Both face milling cutter families are designed for high feed rates per tooth at maximum process reliability. The tools with a medium or large pitch for insert size 12 are designed with carbide shims. These increase the tool life and protect the milling body against damage in the event of an insert fracture. Inclined clamping screws make access easier and shorten the time required to replace inserts.

https://www.walter-tools.com/en-gb/press/news/pages/2021-milling-m5009.aspx

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Milling - Cutting Speed, Feed, and Depth of Cut

Milling Parameter Selection to Lower Specific Cutting Energy During Machining of Alloy Steels
Posted: 5 Mar 2020
The current study focuses on the selection of optimum milling parameters set in Vertical Milling Machine for machining Stainless Steel and Bright Steel, considering Surface Finish and Specific Cutting Energy as output parameters during the process.  The cutting speed, feed, depth of cut, cutter diameter and work material are considered as potential input parameters affecting the output parameters of the milling process.
https://papers.ssrn.com/sol3/papers.cfm?abstract_id=3548412


Optimization of Machining Parameters of Surface Roughness And MRR During Milling of OHNS using Vertical Milling Machine
INTERNATIONAL JOURNAL OF ENGINEERING RESEARCH & TECHNOLOGY
Volume & Issue : Volume 09, Issue 02 (February 2020)
https://www.ijert.org/optimization-of-machining-parameters-of-surface-roughness-and-mrr-during-milling-of-ohns-using-vertical-milling-machine

3/28/2019
High Feed Milling Can Reduce Cycle Times 50 Percent
Sponsored Content
This milling strategy reduces cycle time and tool wear by maintaining high feed rates during aggressive machining passes, even in tough materials like tool steels, titanium and Inconel.
https://www.mmsonline.com/articles/high-feed-milling-can-reduce-cycle-times-50-percent

Milling Cutters

High-feed milling tools – the entire range
March 6, 2020
https://mfgtechupdate.com/2020/03/high-feed-milling-entire-range/

Coatings 2020, 10(3), 235; https://doi.org/10.3390/coatings10030235
Published: 4 March 2020
Recent Advances on Coated Milling Tool Technology—A Comprehensive Review
by Vitor F. C. Sousa andFrancisco J. G. Silva
https://www.mdpi.com/2079-6412/10/3/235/htm

Milling Fixtures

Links to be added

Design and Development of Milling Fixture -
IJREAMwww.ijream.org › papers
PDF
The economical production of engineering components is greatly facilitated by the provision of jigs and fixtures. The use of a jig or fixture makes a fairly simple ...

Design of Milling Fixture in Mass Production of Pivot Block
www.trp.org.in › ARME-Vol.6-No.1-January-June-2017-pp.13-17.pdf
PDF
Keywords: Milling fixture, mass production, CATIA, fixture plate, 3-2-1 principle. I. INTRODUCTION. Fixture is a device for locating, holding, and supporting a work ...

Development and Design of Fixture for Face Milling ... -
ijirsetwww.ijirset.com › upload › february › 88_Development
PDF
Fixture should be designed by considering productivity, time, ease of loading and unloading, accuracy etc. So, the aim is to develop and design the fixture for face milling operation on tool shank which interns increases accuracy of angle, ease of loading and unloading and increases productivity.

(PDF) Productivity improvement by fixture modification
www.researchgate.net › publication › 270648296_Productivity_improv...
systems (FMS), which directly affect machining quality, productivity, and cost of products. Fixtures were developed for job, batch and mass productions, which ...

A Detailed Review on Design and Development of Fixture for ...
www.iosrjournals.org › papers › NCRIME-2018 › Volume-2
PDF
Fixtures reduce the operation time and increases productivity and high quality of ... Though largely used on milling machines, fixtures are also to do this, a fixture ...


Design and Analysis of Milling Fixture for HMC - Krishi Sanskriti
www.krishisanskriti.org › vol_image
PDF
by VS Warule - ‎Cited by 2 - ‎Related articles
Fixture is widely used in the industry practical production because of feature and advantages. To locate and immobilize work pieces for machining, inspection ...

Intelligent Fixtures for Active Chatter Control in Milling
www.sciencedirect.com › science › article › pii › pdf
by L Sallese - ‎2016 - ‎Cited by 9 - ‎Related articles
Chatter vibration represents one of the most limiting factors in assessing the achievable performance, in terms of productivity, of modern machining operations.

A Comparative Study of Chain Clamping Fixture with Other ...
www.matec-conferences.org › pdf › matecconf_icmmr2016_01033
by L Patnaik - ‎2016 - ‎Cited by 1 - ‎Related articles
“Fixture rigidity influences the production rates”. ... demonstrated to improve the productivity and existing fixture rigidity for machining on a gate valve body by.

milling fixtures - Open Source Machine Tools
www.opensourcemachinetools.org › milling_fixtures_MSR_No4_1912
PDF
The first fixture to consider is the milling machine vise, which has a stationary ... as quickly as desirable where cheapness of production is a factor. To overcome ...

Article: Conceptual design and development of pneumatically ...
www.inderscience.com › info › inarticle
by S Gothwal - ‎2018 - ‎Cited by 4 - ‎Related articles
Dec 30, 2017 - Abstract: Fixture performance influences the product manufacturing quality, productivity and cost. Flexible fixtures (FF) provide solution to the problem of costly ... FF and pallets for machining (drilling and milling) operations.

Design and Manufacturing of 8 Cylinder Hydraulic Fixture for ...
cyberleninka.org › article
PDF
by CM Patel - ‎2014 - ‎Cited by 7 - ‎Related articles
Jigs and fixtures are the special production tools which make the standard machine tool, more ... The design of machining fixtures and collet relies on designer.

Improving Machining Productivity of Single Cylinder Engine ...www.ripublication.com › ijaer18
PDF
by V Gulati - ‎2018 - ‎Related articles
increase in machining productivity of ABC machine shop has also been recorded. ... implementation of modifying design of fixture for cycle time reduction to ..

Updated on 24.7.2022, 13 Sep 2020, 11 July 2020