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Explaining it as data-based science is a simple explanation. Many other explanation being offered can be made activities that fall under data-based science.
Jim Gray provided the idea of data-based science. The book, The Fourth Paradigm: A Focus on Data-Intensive Systems and Scientific Communication, is created to examine his thinking on the issue.
In Jim Gray’s last talk to the Computer Science and Telecommunications Board on January 11, 2007, he described his vision of the fourth paradigm of scientific research. He outlined a two-part plea for the funding of tools for data capture, curation, and analysis, and for a communication and publication infrastructure. He argued for the establishment of modern stores for data and documents that are on par with traditional libraries.
Data-intensive science consists of three basic activities: capture, curation, and analysis. Data comes in all scales and shapes, covering experiments that include, large international experiments; cross-laboratory, single-laboratory, and individual observations. Data also comes from normal transactions people and business firms make and potentially individuals’ lives and firms' activities can also become data. The dream of establishing a “sensors everywhere” data infrastructure will support new modes of scientific research.
Data-based research is part of empirical research. But somebody may argue, it can be part of theoretical research, as the researcher may not specially collect data. But research based on secondary data is classified as empirical research only. Theoretical research takes the theories created by others as the inputs and critically analyzes them to propose modifications and improvements.
So far, in practice, data science is doing business research. Not many scientific theories are so far published based on data science. It means academic scientific community has not yet recognized the potential of this new paradigm of scientific enquiry.
Engis Corporation is a third-generation privately-owned US-based manufacturer of high-performance superabrasive lapping, grinding, honing, and polishing products and related machinery and accessories.
Advanced Process Development
We design and engineer custom processes and solutions for the manufacturing industry. We support companies in the agricultural, aerospace, automotive, electronic devices, medical and dental, optics, photonics, military and defense, and much more. We thrive on transforming your raw materials into products.
Our Advanced Process Development services will unlock the real value of partnering with Engis. If you have a challenging part or are looking to improve your current process, our application experts are ready to help, using our state-of-the-art laboratory facilities and metrology. Because we are a complete solutions provider, we can run your parts, and recommend the entire system required to achieve the results: machine, accessories, consumables, process conditions, and training. If you decide to purchase a system from us, we always offer training at our facility as a free-of-charge service to make sure you get the results you are expecting.
If you have an application of interest, please click on the Process Questionnaire and submit your inquiry. We will get back to you shortly.
United Grinding Group
23 Sep 2020
Forward-Looking Grinding Technologies
United Grinding Group presented nine new grinding systems for manufacturers of tools, dies, couplings, and other precision parts.
A minimum number of 12 courses is required to earn the Master of Engineering Management degree. Among them are:
Required Courses (7 Courses)
MEM 402: Engineering Management
MEM 403: Accounting for Engineers
MEM 404: Financial Issues for Engineers
MEM 405: Marketing Issues for Engineers
MEM 407: Decision Tools for Managers
MEM 424: Leadership and Organizational Behavior*
MEM 437: Strategic Management for Engineers
Advanced Engineering Methods for Management (2 Courses)
You must select at least two from this list of advanced engineering courses. These courses differentiate MEM from other business programs because they rely on your engineering or quantitative background. These are courses that will help you get in-depth knowledge in the field you want to pursue in the future.
MEM 410: Managerial Analytics
MEM 412: Operations Excellence
MEM 414: Supply Chain Management (offered every other year)
MEM 415: Computer Simulation for Risk & Operations Analysis (offered every other year)
MEM 416: Business Process Change Management
MEM 417: Product Development
MEM 420: Organizing for Innovation
MEM 426: Project Management
MEM 490: Product Management
ENTREP 495: NUvention Medical (Two course sequence, only one can be applied to AEM requirement)
ENTREP 490: NUvention Transportation
ENTREP 473: NUvention Web (Two course sequence, only one can be applied to AEM requirement)
ISEN 430: NUvention Energy
ENTREP 475: NUvention Analytics
MSIT 423: Data Science for Business Intelligence
Electives (3 Courses)
You choose three electives from a variety of courses within MEM and programs within Northwestern University (limit of two courses from outside the engineering school). These courses give you the flexibility to tailor the program to meet your needs. You may choose courses from:
MEM Electives:
MEM 419: Technical Entrepreneurship
MEM 429: Negotiation for Engineers
Other Schools/Departments have limited courses available:
Department of Industrial Engineering & Management Sciences
Kellogg School of Management
Learning and Organizational Change Program from the School of Education and Social Policy
Optimizing cutting tool technology has a major influence on the productivity and economics of a process. Right cutting tool design and grinding or insert allow higher cutting speed, feed and depth of cut, produce parts of consistent quality and provide predictable long tool lives.
20% increase in the material removal rate could reduce the total cost per component in machining by 15%. Hence, industrial engineers in their productivity engineering of processes can develop and evaluate multiple alternative tool designs and materials to select the best material and tool design. Along with the tool design, tool holder design or selection is also important to use the higher speeds.
The issues of cutting tool materials are discussed in detail in:
At present, turning is most commonly carried out using indexable inserts. Proper selection of inserts and tool holder is required for the best performance.
Indexable Inserts
The following parameters must be selected for inserts:
1. Insert material and grade
2. Insert shape
3. Insert size
4. Insert thickness
5. Corner geometry (nose radius or flat)
6. Groove (chipbreaker) geometry
7. Edge preparation
8. Edge clamping/holding method
9. Lead, rake, relief, and inclination angles
In selection of insert and toolholder for a given operation, the following factors determine technical feasibility and economic benefit.
1. Type of operation (roughing, finishing, etc.)
2. Continuous versus interrupted cut
3. Workpiece material and primary manufacturing. process used to produce the workpiece (casting, forging, etc.)
4. Condition of the machine tool
5. Required tolerance
6. Feeds and speeds
Insert Shape
The shape of an insert is specified by the first letter of the insert designation.
Available insert shapes include diamond (C), octagon, round (R), square (S), triangle (T), and trigon (W). SNGA-532 represents a square insert, and a TPGT-322 is a triangular insert.
The shape of an insert largely determines its strength, its number of cutting edges, and its cost. Round inserts provide maximum edge strength and are therefore a good choice for roughing operations. They also provide a maximum number of effective cutting edges since they can be rotated (or indexed) through small angles when a given edge wears out. Round inserts thin the chip, however, and generate high radial forces; as a result, they should not be used when chatter or instability are expected, or when tight tolerances are required.
Square inserts are common in many applications because they provide good edge strength and a large number of cutting edges (8 for a negative rake tool, 4 for a positive rake). A 80° diamond insert is very versatile because it performs turning with 90° shoulder and facing operations. Generally, the largest included angle suitable for the workpiece geometry should be used. As a general rule, an insert becomes stronger and dissipates heat more rapidly as its included angle is increased. The selection of the included angle is limited by the part configuration, the required tolerances, the workpiece material, and the amount of material to be removed. Insert shape selection involves a trade-off between strength and versatility.
Round Inserts - Benefits
Round inserts offer advantages for the machining of cobalt chromium and titanium implants. In internal turning of the spherical cup in a ball and socket hip joint, round inserts offer a more productive roughing process. They double productivity and reduce tooling costs by a third.
In roughing applications the round shape imparts a strong cutting edge and excellent resistance to excessive notch wear. Choosing round inserts gives secure, quality, reliable machining. It increases life of tool, results in fewer tool changes and trouble free machining.
Applying a round insert with an approach angle of less than κr 45º significantly reduces notch wear, a common problem which leads to an inferior quality component and a reduction in productivity.
Increase feed and speed for maximum productivity: By using a round insert with the depth of cut below the radius, the chip thickness hex is reduced relative to feed and the cutting edge length increased. This results in lower temperatures being generated and the opportunity to increase both feed and speed for maximum production.
Doubling of Productivity by Using Round Inserts - An illustration
Japan’s 2019 strategy for AI points out the need to train 250,000 people annually in fields such as data science and AI.
Employers also need business translators along with tech experts. Business translators are people who can match technology with business priorities to help transform operations. Effective business translators understand industry trends and market needs and guide potential innovations in products and processes based on new technologies. They also help in educating customers and employees on the benefits of automation and find ways to foster growth while minimizing disruption. To fill the urgent need for people with these skill sets, the best option is often to help employees with skills in business development to develop understanding of digital technologies and capabilities.
Deming reemphasizes many things that F.W. Taylor advocated. But, be sure, every new successful scholar and researcher develops things in more detail to give more effectiveness and efficiency in the system. Many times, the original thinkers have not claimed any conflict with may earlier theories. But subsequent marketers who follow the new gurus create conflict theories as marketing strategies.
Alternatives to existing machining practices can be found for each of the issues discussed in various chapters in the metal cutting theory. Identifying the alternatives requires knowledge of the content given in the chapters and additional content of the developments in recent through reading of magazines and research papers and catalogues provided by various suppliers and creativity.
Adapting Cutting Tools To Changing Trends
June 24, 2019
In an interview with Asia Pacific Metalworking Equipment News, Jacob Harpaz, ISCAR CEO, IMC President and Chairman of the Board, discusses the current trends in the metalworking tool industry. https://www.equipment-news.com/adapting-cutting-tools-to-changing-trends/
Developments in Engineering Elements of Manufacturing Operations
Sep 2019
Productivity improvement achievable with the XSYTIN-1 phase toughed ceramic insert from Greenleaf Inc., Saegertown, Pa.: XSYTIN-1 delivered a cycle time of under five minutes milling CGI (compacted graphite iron) versus 20+ plus minutes with a comparable carbide insert. The carbide ran at 500 sfm (152.4 m/min) with a feed rate of 0.006″ (0.15 mm) per tooth and a DOC of 0.0060″ (0.15mm) while XSYTIN ran at 1,900 sfm (580 m/min) with a feed of 0.0085″ (0.22 mm) per tooth and the same DOC. https://www.sme.org/technologies/articles/2019/september/revving-up-tooling-and-machining-strategies-for-auto-parts/
August 2019
The tools worked at 4500 min-1 speed. This resulted in a cutting speed of between 453 and 1336 m/min. The tooth feeds per revolution are between 0.022 mm and 0.087 mm. The decisive advantage is the reduced processing time of only 7 s compared to 160 s previously when carbide tools were used. https://www.spotlightmetal.com/much-more-productive-with-pcd-for-aluminum-a-851042/
Books on Metal Cutting
CNC Programming for Machining
The book is basically written with a view to project Computer Numerical Control Programming (CNC) Programming for machines. This book shows how to write, read and understand such programs for modernizating manufacturing machines.
Kaushik Kumar, Chikesh Ranjan, J. Paulo Davim - 2020 - Preview https://books.google.co.in/books?id=o67QDwAAQBAJ
Theory and Practice in Machining Systems
Yoshimi Ito, Takashi Matsumura
Springer, 05-Apr-2017 - Technology & Engineering - 292 pages
This book describes machining technology from a wider perspective by considering it within the machining space. Machining technology is one of the metal removal activities that occur at the machining point within the machining space. The machining space consists of structural configuration entities, e.g., the main spindle, the turret head and attachments such the chuck and mandrel, and also the form-generating movement of the machine tool itself.
The book describes fundamental topics, including the form-generating movement of the machine tool and the important roles of the attachments, before moving on to consider the supply of raw materials into the machining space, and the discharge of swarf from it, and then machining technology itself.
Advanced Machining Processes of Metallic Materials: Theory, Modelling and Applications, Second Edition, explores the metal cutting processes with regard to theory and industrial practice. Structured into three parts, the first section provides information on the fundamentals of machining, while the second and third parts include an overview of the effects of the theoretical and experimental considerations in high-level machining technology and a summary of production outputs related to part quality.
In particular, topics discussed include: modern tool materials, mechanical, thermal and tribological aspects of machining, computer simulation of various process phenomena, chip control, monitoring of the cutting state, progressive and hybrid machining operations, as well as practical ways for improving machinability and generation and modeling of surface integrity.
This new edition addresses the present state and future development of machining technologies, and includes expanded coverage on machining operations, such as turning, milling, drilling, and broaching, as well as a new chapter on sustainable machining processes. In addition, the book provides a comprehensive description of metal cutting theory and experimental and modeling techniques, along with basic machining processes and their effective use in a wide range of manufacturing applications.
The research covered here has contributed to a more generalized vision of machining technology, including not only traditional manufacturing tasks, but also potential (emerging) new applications, such as micro and nanotechnology.
Includes new case studies illuminate experimental methods and outputs from different sectors of the manufacturing industry
Presents metal cutting processes that would be applicable for various technical, engineering, and scientific levels
Includes an updated knowledge of standards, cutting tool materials and tools, new machining technologies, relevant machinability records, optimization techniques, and surface integrity
P.285 High Speed - good content
Chapter on machinability similar to Agapiou https://books.google.co.in/books?id=G3Z_CwAAQBAJ
The iTENDO sensory toolholder makes it possible to monitor machining and control cutting parameters in real time, for "a new era of toolholding."
In a first step, Schunk is standardizing the iTendo for the common interface HSK-A 63 with clamping diameters from 6 to 32 mm and a length of 130 mm. The sensory toolholder is suitable for the use of coolant and is designed for speeds of up to 10,000 RPM.
BECHEM Avantin for minimal consumption and stain free machines.
BECHEM’s Avantin metal cutting fluid range are the most advanced breed of cutting fluids that have set new benchmarks in the industry by achieving maximum performance with minimal consumption. Fortified with advanced additives the Avantin series of metal cutting fluids are equipped to contend harsh external impurities such as hydraulic oil, swarf and grinding dust whilst delivering unmatched performance.
BECHEM Avantin 320
Excellent dirt carrying capacity. Suitable for all types of grinding applications and cast iron machining. Has high emulsion stability. Not suitable for aluminium machining.
How to Improve CNC Cutting Tool Efficiency & Increase Tool Life
2020.8.28
The high requirements for CNC parts quality mean that the CNC machining process should focus on productivity and efficiency improvement. With more and more cutting tools used in the modern machine shop, how can we improve the cutting tool efficiency and increase the tool life, check out the following tips for processing optimization.
A revolutionary parting system designed for increased productivity, MULTI-F-GRIP comprises a robust tool block carrying square blades that feature four pockets, with a unique parting concept capable of parting off up to 120mm bar diameter to optimize performance.
DEEPACO GLOBAL PVT LTD (DGPL) IS AN INTEGRATOR OF THREE CORE AREAS OF CNC MACHINING - SOFTWARE, METAL CUTTING TOOLS & INDUSTRIAL PROCESS FLUIDS PROVIDING CUSTOMIZED SOLUTIONS FOR IMPROVING PRODUCTIVITY.
https://www.dgplindia.in/about
Productivity with FreeMove: A Machine Tending Case Study—Part 1
Impact of nose radius and machining parameters on surface roughness, tool wear and tool life during turning of AA7075/SiC composites for green manufacturing
Rajesh Kumar Bhushan
Mechanics of Advanced Materials and Modern Processes volume 6, Article number: 1 (2020)
Obtain in-depth information at any granularity about production rates, availability scores and generate overall equipment effectiveness for a single machine, plant or even compare plants with our nifty Productivity Monitoring Module. The actionable insights are certain to translate into ROI and identification of bottlenecks in production. Improve the morale of your workforce by aligning business goals with incentives carved out of the data this solution provides.
https://embedsense.com/machpro/
Mastercam is the most popular CAM software in India, claims Vineet Seth, Managing Director – South Asia & Middle East, Mastercam APAC in an interview with OEM Update.
Applying A High Speed Machining Discipline of Understanding Why Chatter Occurs Helped a Company.
In this shop, high speed machining thinking made sense even at 4,000 rpm. While the disciplines the shop put in place made a new 15,000-rpm profiler dramatically more productive. But, high speed machining thinking would have remained valuable even if the new machine never came. Acoording to a co-owner of this shop, high speed machining thinking has no need for speed to deliver results.
CoroDrill 860 with enhanced -GM geometry, a new design solid carbide drill that’s optimized for a wide range of materials and applications, across all industry sectors.
HARDINGE INTRODUCES THE TALENT® TT (TWIN-TURRET) CNC MULTI-TASKING LATHE
July 15, 2020
These advanced level turning centers feature twin spindles and twin 16 station turrets for increased productivity, improved part throughput, improved part accuracy, reduced parts handling and reduced part cycle times to increase your profit levels. The machines feature an orthogonal Y axis on the top turret and all stations on both turrets can be live capable for prismatic milling capability.
In the pandemic tool manufacturers trying to do best.
July 8, 2020
To machine super alloys, since they generate a lot of heat – coolant plays an important role. We designed and launched tool holders, TungTurnJet, which directs the coolant to the cutting zone thereby increasing tool life. We also launched CBN grade, BX815 for super alloys which can run at 250m/min which is unimaginable.
How MSP and Renishaw Cut 3T-am's additive manufactured Part Setup Time and Improved Productivity
MSP recently worked with Renishaw PLC to automate part setup and improve productivity for additive manufacturing firm 3T-am, helping to cut part setup time from 5 hours to 10 minutes.
SE60X is a high-performance end mill that is suitable for high-speed milling application for materials between 53 HRC to 68 HRC. Special designed 4/6 Flutes enable 2x or 3x feed rate in comparison with conventional 2 flutes cutter. Tough PVD Silicon-based coating to prolong tool life and enable higher cutting speeds.
HELIDO 800 LINE, A New 80º Rhombic Insert with High Helical Cutting Edge for High Metal Removal Rates
Latest Update July 25, 2020
The HELIDO 800 line is one of the most popular face milling cutters, with 2 shapes of a unique insert, clamped into the same tool pocket. They are: a square double-sided insert with 8 cutting edges and an octagonal double-sided insert with 16 cutting corners.
This family of face mills offers the most economical face milling solution.
Jul 11, 2020 - Chop, High Speed, Stationary Cutting Wheels for metal ... Selecting the best wheel type for your application increases wheel effectiveness and user productivity.
Modelling and optimisation of duplex turning of titanium alloy (grade 5) using Taguchi methodology-response surface methodology
Sunil Kumar, Ravindra Nath Yadav, Raghuvir Kumar
https://doi.org/10.1504/IJISE.2020.108549
Published online 6 July 2020
Duplex turning is an innovative idea of metal cutting that shows potential to improve the productivity with better quality. In duplex turning, two cutting tools are used as parallel to each other and perpendicular to the workpiece axes for getting the desired surface quality in single pass turning operation.
How to Design and Analyze the Right Clamping System
The use of innovative clamping systems to optimize the moldmaking production process requires consideration of five factors based on Industry 4.0 principles.
Our Variable Flow Coolant Pump uses a variable frequency drive to control the speed of our standard centrifugal coolant pump during operation. This allows control of the coolant flow and pressure directly from the program, via M code and P values.
EcoCooling even for the hardest known metals, like chrome, titanium and tungsten carbides.
EcoCooling: Ionized air penetrates the cutting zone and forms a dry lubricant that decreases cutting friction and generated heat, at the same time speeding up the oxide layer formation. The process is patented on all continents.
While reduced metalworking fluid costs are an obvious benefit, there is also the promise of improved productivity through higher cutting speeds, reduced cutting tool wear and reduced maintenance costs.
Investigation of cutting conditions on tool life in shoulder milling of Ti6Al4V using PVD coated micro-grain carbide insert based on design of experiments
Kourosh Tatar,a,∗ Sören Sjöberg,a and Niklas Anderssonb
Heliyon. 2020 Jun; 6(6): e04217.
Published online 2020 Jun 18. doi: 10.1016/j.heliyon.2020.e04217
A Review on the Application of Various MQL Base in Metal Cutting Operation of Aluminum Alloys
Test Engineering and Management 83(May -June 2020):1168 -1174
3 February 2020
How a manufacturing execution system can transform your plant’s efficiency and profitability
In manufacturing, profit is reliant on how efficient the shop floor is. Squeezing everything from your resources without compromising on quality is a challenge increasingly faced by manufacturers. So how can manufacturers stay competitive whilst maintaining or increasing profit?
Aluminum alloys are also among the most machinable of the common metals. Cutting forces are generally low, cutting temperatures are kept low because aluminum is a good heat conductor and most alloys melt at temperatures between 500°C and 600°C, and therefore tool wear rates are also low.
When cut under proper conditions with sharp tools, aluminum alloys acquire fine finishes through turning, boring, and milling, minimizing the necessity for grinding and polishing operations.
Tools Used: Aluminum is commonly machined with HSS, carbide, and PCD tooling.
Not used: Silicon nitride-based ceramic tools are not used with aluminum because of the high solubility of silicon in aluminum.
Two major classes of commonly machined aluminum alloys are cast alloys, used especially in
automotive powertrain and component manufacture, and wrought or cold worked alloys, used in
airframe manufacture and similar structural applications.
The most commonly machined cast aluminum alloys by volume are cast aluminum-silicon alloys,
which are used extensively in automotive applications. From a machining viewpoint it is common
to distinguish between eutectic alloys, containing 6%–12% silicon, and hypereutectic alloys containing generally 17%–23% silicon.
Some of the eutectic alloys are 319, 356, 380, 383, and most piston alloys. From a tool life viewpoint, most eutectic alloys, when properly tempered, present few difficulties, so that long tool life can be achieved at relatively high cutting speeds. Tool life approaching one million parts can be obtained in some mass production operations using PCD tooling.
Cutting Speeds: Speeds up to 450 m/min can be used when turning with carbide tools, and speeds as high as 4000 m/min can be achieved in some milling applications with PCD tooling. Of the common eutectic alloys, the most easily machined are 319 and 380.
MACHINABILITY OF FCD 500 DUCTILE CAST IRON USING COATED CARBIDE TOOL IN DRY MACHINING CONDITION
Jaharah Abd. Ghani, Mohd Nor Azmi Mohd Rodzi, +2 authors Che Hassan Che Haron
Published 2009
Materials Science
In this study, ductile cast iron grade FCD 500 was machined using carbide cutting tool in dry end milling condition. The end milling parameters used were cutting speed of 180 m/min, 210 m/min dan 260 m/min. The feed rate of 0.10 mm/tooth, 0.25 mm/ tooth and 0.40 mm/ tooth, and the depth of cut of 0.30 mm, 0.60 mm dan 0.90 mm.
The workpiece material used in the present work was austenitic stainless steel (grade SUS 304) with an approximate composition of 0.08% C, 2% Mn, 10% Ni and 19% Cr. The diameter and length of the workpiece were 200 and 500 mm, respectively. Titanium nitride coated cermet tool inserts (SNMG 120408-HM, grade 200) were used. The cermet tools were mechanically clamped to the tool holder. Geometrical parameters of the inserts were as follows: relief angle-4°, rake angle-10°, principal cutting edge angle-85° and auxiliary cutting edge angle-5°.
The experiments were conducted on a lathe model Harrison M390. Cutting parameters were selected to cover roughing, finishing and fine finishing. Metal cutting was performed at cutting speeds of 300, 400, 500 and 700 m min-1. Feed rates were 0.05, 0.1, 0.2 and 0.4 mm rev-1. Depths of cut tried were 0.1, 0.2, 0.3 and 0.5 mm. A full factorial set of experiments (64 trials) was performed with 4 different cutting speeds, 4 levels of depth of cut and 4 levels of feed rates. Each insert of the cutting tool had 8 edges (4 on each side). Thus each insert was capable of performing 8 trials.
Ahsan Ali Khan and Sami Salama Hajjaj , 2006. Capabilities of Cermets Tools for High Speed Machining of Austenitic Stainless Steel. Journal of Applied Sciences, 6: 779-784. https://scialert.net/fulltext/?doi=jas.2006.779.784
Nickel-based Superalloys
PCBN Performance in High Speed Finishing Turning
of Inconel 718
José Díaz-Álvarez ID , Víctor Criado ID , Henar Miguélez and José Luis Cantero
Metals 2018, 8, 582; doi:10.3390/met8080582
Nickel-based superalloys with excellent mechanical properties at high temperature and corrosion
resistance find a wide range of applications such as aircraft engines power-generation turbines, nuclear power generation, and chemical processes. Machining difficulties arise in cutting these alloys due to strong work hardening, presence of hard carbides, and low thermal conductivity leading to high temperatures during machining.
Selection of proper tool material, geometry, coating; cooling strategy; and cutting parameters (cutting speed and feed) strongly determine tool wear evolution and surface integrity.
The candidate tool materials are cemented tungsten carbides, ceramics, and cubic boron nitride (CBN) used in rough machining of Ni superalloys. Carbide tools are restricted to cut in the range between 30 m/min to 70 m/min because of their poor thermochemical stability, however they can be used at high values of feed due to its toughness. Ceramic tools based on alumina (aluminum oxide, Al2O3) and silicon nitride (Si3N4), are suitable. Alumina combined with TiC improve thermal properties of the insert allowing the increase of cutting speed about five times higher than the carbide tools (120–240 m/min), although thermal and mechanical shock resistance are not significantly improved compared to tungsten carbides. Whisker-reinforced alumina ceramics (Al2O3 + SiCw) can reach cutting speeds in the range between 200 and 750 m/min and feed between 0.18 and 0.375 mm/rev and present improved toughness. Silicon nitride, with low thermal expansion and elevated toughness, allows machining at higher speeds and feed than alumina. Finally, cubic boron nitride (CBN) can be used to machine nickel- or boron-based superalloys with hardnesses greater than 35 HRC at cutting speeds ranging from 200 to 350 m/min.
A detailed investigation of residual stresses after milling Inconel 718 using typical production parameters for assessment of affected depth
JonasHolmbergabAndersWretlandcJohanBerglundaTomasBeno
Materials Today Communications
Volume 24, September 2020, 100958 https://www.sciencedirect.com/science/article/pii/S2352492819309377
Titanium
Makino's New HMC for Titanium Machining
Purpose-built with rigidity, dynamic stiffness, vibration damping, and agility
Gente and Hoffmeiste [2001] reported the chip formation of Ti–6Al-4V at very high cutting speed, ranging between 30 m/min and 6,000 m/min According to experimental results, the structure of segmentation was changed at the cutting speed exceeding 2,000 m/min. Furthermore; no change in specific cutting energy coincides with this change in structure.
Gente A, Hoffmeister HW, Evans C (2001) Chip formation in machining Ti6Al4V at
extremely high cutting speeds. CIRP Ann Manuf Technol 50:49–52. doi:10.1016/
S0007-8506(07)62068-X
Machinability of a material can be defined as the ease with which it can be machined.
Machinability depends on the physical properties.
Machinability can be expressed as a percentage or a normalized value. The American Iron and Steel Institute (AISI) has determined AISI No. 1112 carbon steel a machinability rating of 100%.
Machinability of some common materials in the scale: AISI No. 1112 = 100 are given below. below:
2. Minimize the number of machined features 3. Minimize the machined stock allowance 4. Optimal dimensional and surface finish tolerances 5. Standardize features 6. Minimize the number of machined orientations 7. Provide adequate accessibility 8. Provide adequate strength and stiffness 9. Provide surfaces for clamping and fixturing
The story of toolholder change at Wescast Industries Inc., the world’s largest manufacturer of cast exhaust manifolds and turbocharger housings for passenger cars and light trucks.
The annual cost-savings for change of toolholder, from the additional tool life on Wescast’s 16 CNC machine line, factoring direct and indirect labor costs as well as tool change savings, was $78,269.
The new toolholder was Haimer's shrink fit toolholder. The regional manager for HAIMER USA, presented Wescast with a proposal that would guarantee both increased productivity and tool life versus their current collet chuck holders. He promised reducing cycle time by 5% for all round tools with the guarantee that Wescast would net a minimum increase in tool life of 25% for all tools using shrink chucks.
The Test
To test the proposal, one machining cell (8 machines) and five cutting tools was used to conduct a study. The part was cast iron exhaust manifolds. In four machines, the existing collet chuck holders were left to run as usual, without changing cutting parameters. In the other four machines, HAIMER shrink fit chucks replaced the pre-existing collet chucks with adjustments to feeds and speeds to generate the 5% improvement for each tool. During the following three months, data was carefully gathered as all machines continued operating across three shifts, six to seven days per week. Data including cycle times, tool life and tool change times were recorded.
Results – Tool Life
After three months, the data was examined. The improvements in tool life from the tools in shrink fit chucks were profound, achieving an average life increase of 60% across all five tools. Tool life, which was measured by the number of manifold pairs the tools could produce, increased anywhere from 25% to 100% depending on the tool. The annual cost-savings from the additional tool life on Wescast’s 16 CNC machine line, factoring direct and indirect labor costs as well as tool change savings, was $78,269.
HAIMER claims the significant increase in life is a bi-product of their systems runout accuracy, balance integrity, taper accuracy and inherent ability to maintain the aforementioned properties from one tool change to the next.
Application of Tribos Toolholder for Productivity Improvement
Hard Milling - Productivity Improvement Using Tool Clamping Solution
A combination of toolholding used to get the most performance from its small-diameter tools.
Impact Forge in Columbus, Indiana, faced a toolholding challenge. The shop runs small tools at long overhang lengths on jobs that involve not just restricted tool access, but also hard material.
The application is machining forging dies. that have been repaired through flood welding. Process engineering programmer has to develop process plan for material with hardness reaching as high as 50 Rc.
Roughing and finishing occur on Okuma horizontal machining centers. Roughing is done using a 1-inch diameter end mill in a setscrew holder. Finishing the fine details of the dies calling for end mills as small as 0.030 inch in diameter. Deep cavities and small relief angles for the cavity walls require a toolholder slender enough to let these small tools get close to the walls to do their work.
Slender shrink-fit toolholders were first tried. The shrink-fit holder uses thermal expansion and contraction. The holder is heated to open the bore, which then shrinks during cooling to clamp around the tool. The shrink fit’s clamping force is proportional to the amount of expansion and contraction, which is proportional to the size of the bore. As the tool holding bores are small in case of small tools, the clamping force was small. The shrink-fit holders are not able to clamp the the tiny tools if the cutting force became too high at the high speeds used. The toolholder became the limiting factor for productivity of the machine.
Search for the solution to the problem led to the trial using the “Tribos” system from Schunk (Morrisville, North Carolina). The proprietary tool clamping system uses metal spring-back to clamp the tool in a way that is similar to shrink fit, except that it uses mechanical force to open the bore instead of heat. The other part of solution was to hold the Tribos extension within a hydraulic toolholder. The shop used “Tendo” hydraulic toolholders, also from Schunk. A hydraulic toolholder uses hydraulic pressure to deliver its force. The toolholder contains a reservoir of hydraulic fluid. By tightening a screw, the user applies pressure to this fluid, and that pressure is in turn distributed around the metal sleeve, or bush, that holds the tool’s shank. The compression of this flexible bush clamps the tool. In addition, the hydraulic fluid provides vibration damping as a secondary benefit. This damping for the tool life improvement according to shop's process planners.
The Tribos toolholder’s bore has a natural shape that is considerably distorted from being a perfect circle. Instead, the shape has three lobes. The clamping device applies force to the toolholder to push this shape closer to being a circle and the tool can be inserted. Releasing the force then lets the toolholder spring back, concentrically clamping the tool.
With this tool clamping and holding solution, the shop was able to run one of the 0.030-inch Melin ballnose tools in 50 Rc steel at 8,500 rpm, 20 ipm and 0.003-inch depth of cut. The parameters were used and productivity improved substantially.
Rego-Fix ER Collets for Tools - Productivity Improvement Case Study
Case Study 34
October 2011
A manufacturing engineer at Smith & Wesson, took a hard look at the company's revolver frame machining operations and realized that toolholding was not allowing machine tools to run at their maximum RPM. The culprits were cutting tool deflection and runout, so machines have to be run slower during heavy milling to maintain part quality. In case of aluminum revolver frames machined on 4-axis horizontal milling machines with CAT 40 spindles with standard ER collets for holding cutters, machine spindle speed during rough milling operations was restricted to just 5,000 RPM on machines rated to run at 10,000 RPM.
Fermer Precision (Ilion, New York) machines a variety of precision parts from aluminum, cast iron, powdered metal, carbon steel and low-carbon steel for automobiles, firearms, medical products and train brake systems. The company uses a Mori Seiki SV-500 and two OKK KVC 600 vertical machining centers for drilling, reaming and chamfering operations. A typical drilling operation requires drilling nine holes in six workpieces mounted in a single fixture.
The powdered-metal core drills presently used were supposed to last 200 parts per drill, but they were only averaging 120. Operators were at risk of burning their hands when removing the tooling from the shrink-fit toolholders. If tools with steel shanks were used instead of solid carbide, the coefficient of expansion of the toolholder and the tool's steel shank are too close to the same and hence there was difficulty in removing the tool. In most cases, you need to use a mallet and a drive punch to remove the tool. After removal of the drill, the toolholder still could not be used for another 1.5 hours till it . cools down enough for handling and then retooling. During the reheating and cooling of the shrink-fit toolholder, operators ran the risk of injury.
The long retooling times are forcing the firm to keep on hand three times the number of toolholders actually needed for drilling. One is cooling, one is working and the third one is ready for the next change. The company was looking for alternatives and DoAll and Sandvik Coromant (Fair Lawn, New Jersey) team came out with a suggestion. The solution suggested was a hydromechanical clamping toolholder and a dual-grade drill with high toughness and good wear resistance—Sandvik's Delta C GC1020 drill and the Sandvik CoroGrip toolholder.
The key to the new drill's performance is the sintering of two substrate materials together at the drill tip. The grade at the tool center provides toughness and withstands tension and pressure on the drill point. The grade at the tool periphery provides wear resistance at high surface speed. This combination results in high speeds and feeds without sacrificing edge security. The CoroGrip high precision chuck for high speed machining offers twice the clamping force of shrink-fit chucks and three times that of ordinary hydraulic chucks.
The tooling combination demonstrated dramatically longer tool life. The average number of parts each drill handled increased from 120 to 300. The increase in tool life varied from 50 to 200 percent on tool life in different applications.
The runout on the CoroGrip is 0.002 mm and is another benefit.
Feeds and speeds on the machines remain unchanged with the new drill and toolholder. A typical operation is drilling several 0.4313-inch diameter holes, 1 ¾ inch deep at 250 sfm in low-carbon steel workpieces.
Fermer technicians were happy with the safe, easy and quick tooling setup with the CoroGrip chucks. The toolholders are fitted with a tool and ready for insertion into the machines in just 15 seconds which is 360 times faster than the setup time required for the shrink-fit toolholders.
Fermer no longer needs to inventory more toolholders. The gloves and mallet are no longer necessary to change drills. During tool setup there are no forces exerted on the clamp or the tool pot, since only shop air is applied to move internal toolholder components.
The design of the CoroGrip toolholder optimizes balance and torque transmission. The combination has increased overall productivity and the quality of our products according to executives of Fermer.
Collet for CoroChuck® 930 maximizes pull-out prevention
The new collet features mechanical locking interface
Cutting tool and tooling system specialist Sandvik Coromant has introduced a new collet for its CoroChuck® 930 high-precision hydraulic chuck. Designed to suit Weldon shanks, the new collet features a mechanical locking interface to prevent tool pull-out or movement when producing expensive components and/or machining with challenging cutting data
“Being 100% assured of zero pull-out for Weldon shanks when producing high value-added parts, such as aerospace frame and engine components, is paramount in the highly competitive manufacturing arena,” says Mats Backman Global Product Manager at Sandvik Coromant. “Production engineers and managers are under constant pressure to minimize scrap and maximize bottom-line profitability. These thoughts were the driver for developing the new collet.”
The mechanical locking interface acts between the collet and chuck, and between the collet and shank. Having confidence in no pull-out when both collet and chuck are locked enables increased productivity in heavy-duty applications. Further benefits include easy assembly into CoroChuck 930 chucks, both slender and HD versions, while high run-out accuracy is assured with cylindrical clamping of Weldon shanks. In addition, coolant supply through the collet provides secure and reliable coolant delivery to the tool.
Ultimately, this new solution will benefit any machine shop seeking trouble-free machining in heavy applications. No pull-out or tool movement protects against the potentially sizable cost of reworking or scrapping an expensive component. Pull-out effectively changes the gauge length of the tool mid-cut, leading to the generation of features with incorrect dimensions or crash marks.
Example of the potential gains on offer - Customer Use Case
A customer case trial saw CoroChuck 930 (featuring the new collet) used for a milling operation on a CNC turn-mill machine. The objective was to produce a twin-screw from 42CrMo4 alloy steel. At cutting data of 3220 rpm spindle speed, 1500 mm/min (590 in/min) feed speed, 10 mm (0.394 inch) axial depth of cut (nominal), and 20 mm (0.787 inch) radial depth of cut, the mechanical locking interface generated a stable process with no pull-out. In addition, productivity increased due to longer tool life.
Collets are available to suit an assortment of common Weldon shank sizes. Accessories include assembly tools and anchor screws.
For more information please visit: https://www.sandvik.coromant.com/en-gb/products/corochuck_930/pages/default.aspx
