Lesson 106 of Industrial Engineering ONLINE Course.
Refer to Industrial Engineering Case Studies Collection for case studies and productivity engineering applications
Industrial engineers have to first know currently available alternatives to produce to specification. Then the best alternative to give highest productivity can be selected. Further industrial engineers have to continuously think using the basic principles of relevant engineering decision to come up with more productive alternatives.
Increasing productivity of each and every input is to be attempted by industrial engineers.
Productivity Analysis - Productivity Engineering
Productivity analysis provides ideas for productivity improvement using new tools or making modifications in existing tools or in the way they are being used.
Productivity engineering needs to be undertaken to use new or modified tools and also to select new tools which are appropriate. Some examples of productivity improvement are being provided in this collection to give a direction to productivity engineering efforts related to metal cutting tools. Learn the work involved in productivity engineering by studying examples of productivity engineering.
Productivity Improvement Using Alternative Boring Heads
Case Study 31
Productivity-boosting boring heads
Kip Hanson
April 1, 2015
Boring can be done at higher speeds. With the growth of high-speed spindles, boring heads are spinning faster. Yet the often nonsymmetrical construction of boring heads can make them wobble and vibrate when run beyond a few thousand rpm—especially single-edge finishing heads.
BIG Kaiser Precision Tooling Inc., Hoffman Estates, Ill., provides auto-balancing heads are a must-have for these situations. They use a pinion gear to move a counterweight—as the cutting edge slides in one direction along with the cartridge (the insert holder), the weight moves opposite to it, keeping the head balanced for whatever diameter bored.
For deep-hole finishing, Smart Damper tools are to be used in conjunction with auto-balance heads. The Smart Damper is BIG Kaiser’s solution for chatter, a common occurrence as boring depth increases. Damping often becomes necessary at length-to-diameter ratios of 8:1 and higher. Damping allows for a heavier DOC and feed rate, sometimes two to three times that of an undamped boring head. Thus higher spindle speeds can be used, feed rate and depth of cut are also increased giving higher productivity.
The Smart Damper series covers hole diameters from 1.625 " to 4 ", and up to 16 " deep.
https://www.ctemag.com/news/articles/productivity-boosting-boring-heads
https://www.bigkaiser.com/en/products/boring-tools/modular-components/damping-bars
Sep 2019
Adding an edge to boring bar machining
https://www.pesmedia.com/yamazaki-mazak-rigibore-vcn-530c-machining-centre-activeedge-boring-bar-system/
BIG KAISER boring head with built-in smart damper for fast, vibration-free operation
November 23, 2016https://mfgtechupdate.com/2016/11/big-kaiser-boring-head-built-smart-damper-fast-vibration-free-operation/
Asymmetric boring increases productivity, reduces costs
May 14, 2015A geometric leap forward, asymmetric line boring accentuates the advantages of reaming and line boring of items such as engine blocks, while eliminating disadvantages.
https://www.todaysmotorvehicles.com/article/tmv0515-asymmetric-line-boring/
https://nraoiekc.blogspot.com/2020/06/productivity-improvement-using.html
Productivity Engineering requires experiments, data and decision making among alternative tools.
High Feed Rate Milling Choices - High Feed Rates or Deep Cuts - Which is Faster? - Case Study
9/22/2021
https://www.mmsonline.com/articles/high-feed-rates-or-deep-cuts---which-is-faster
Cutting tool case studies
https://www.productionmachining.com/zones/browse/cutting-forming-tools/9
News of New Cutting Tools
Cutting Tool Engineering Magazine
2024
September 03, 2024
ShareAM Type Insert
Tungaloy Corporation announces the addition of the "AM Type" insert for non-ferrous metal machining to its center blade multi-functional cutter "DoMultiRec".
ShareAM Type Insert
Tungaloy Corporation announces the addition of the "AM Type" insert for non-ferrous metal machining to its center blade multi-functional cutter "DoMultiRec".
The new "AM Type" insert is designed for non-ferrous metal machining, featuring a sharp cutting edge achieved through ground peripheral surface and polished rake face to a mirror-like finish. This design reduces built-up edge during machining and ensures a high-quality, glossy surface finish. The insert grade "KS05F" is a fine-grained carbide that balances wear resistance and chipping resistance, providing exceptional reliability and stable performance across a wide range of applications.
The addition of the "AM Type" insert to the "DoMultiRec" series will greatly contribute to tool consolidation and productivity improvement for a wider range of industries.
2023
New products for spring 2023 from ZCC Cutting Tools
20th anniversary in 2023, the European central operations of the largest Chinese manufacturer of carbide tools is expanding its portfolio of insert milling and turning solutions to meet the needs of its target group. Now in its 20th year in Europe, the company’s newly presented products are increasingly focused on aerospace as well as die and mould making.
New YBG205H turning grade for steel and stainless steel
With the addition of the YBG205H grade to its line-up, ZCC-CT Europe now offers a highly temperature-resistant grade for turning applications primarily involving steel and stainless steel. The thin TiAlSiN PVD coating provides optimised coating stability for extremely long tool lives. At the same time, the ultra-thin layer structure guarantees optimally defined and prepared cutting edges for smooth cuts. The new YBG205H grade will initially be available as C-, D-, T- and W-shaped inserts.
New MU chip breaker
The MU chip breaker’s 3D-optimised chip-forming elements ensure maximum chip control, which is relevant and important for grooving as well as parting and grooving applications. This, in combination with the highly stable cutting edge achieved, among other things, thanks to harmonised and optimised macro and micro geometries, allow the MU chip breakers from ZCC Cutting Tools Europe to provide even greater flexibility in your applications. A reduction in surface contact, which is made possible by optimised chip-forming elements, results in even less wear, making MU chip breakers well suited for machining a full range of materials – from steel and stainless steel to cast iron and high-alloy materials.
New FME17 face milling system
The new FME17 face milling system from ZCC Cutting Tools Europe was developed specially for common roughing and finishing operations on contours and end faces with high demands in terms of surface quality. It is currently available in diameters of 50 to 400 mm. In combination with eight-edged negative inserts, the 75° milling system delivers enhanced cutting edge stability. New chip breakers for roughing, finishing and general machining operations also provide a positive cutting geometry with correspondingly lower cutting forces, while the open chip former design ensures controlled chip removal. Available in four grades for applications involving steel, stainless steel, cast iron and high-temperature-resistant materials, the newly designed SN*X inserts offer enhanced resistance to breakage along with an accompanying increase in process reliability. The SNMX120512-* inserts can also be used with two other ZCC Cutting Tools Europe milling systems (FMA17/FMP17), helping to reduce the number of variants and keep costs in check.
Redesigned EMP05 plunge milling system
The ultra-versatile system for grooving and plunge milling applications is able to meet the full range of requirements in machine/plant engineering and, above all else because it is well suited for ramping, in mould and die making. Extremely deep grooves are also possible at diameters ranging from 16 to 50 mm when the system is equipped with two inserts. Available as end mills or indexable heads, the tools from ZCC Cutting Tools Europe are also suitable for use in groove milling operations.
The high-performance standard grades that the ADKT* inserts for general machining applications are available in are intended for machining operations involving steel, stainless steel and cast iron.
New FMR06 round insert milling cutter
It guarantees maximum stability in facing operations in which solid CBN and ceramic round inserts are employed. Developed for use in die and mould making operations and in aerospace applications, the easy-to-use wedge clamping system delivers the reliability you need, even in highly demanding applications. In addition, an integrated air cooling system improves chip removal. Available in the standard 50–125 mm diameter range, two mixed ceramic, an Si3N4 ceramic, an SiAlON ceramic and a solid CBN grade are available for high removal rates and provide the process reliability required for machining hard materials, superalloys and cast iron.
New CSX1000 grade for turning and milling superalloys
CSX1000 is a high-performance grade from the latest generation of SiAlON ceramic cutting materials. It combines toughness and wear resistance, making it suitable for milling operations performed, for example, on ZCC Cutting Tools Europe’s FMR06 round insert milling system and for turning applications, especially in medium machining through to roughing operations involving heat-resistant alloys. The cutting edge is optimally prepared for such applications, resulting in a significant improvement in wear resistance and very long tool lives. Additional cutting edge designs are also available for other applications.
New APL universal chip breaker
Thanks to its universal geometry, the APL chip breaker from ZCC Cutting Tools Europe is available for a wide variety of applications involving materials ranging from steel and stainless steel to cast iron. Plus, thanks to the available nose radii (0.4–2.0 mm), the insert sizes on offer and the three different grades that users can currently choose from, it is able to handle a whole host of milling operations. The APKT* inserts can also be used in three ZCC Cutting Tools Europe milling systems (EMP01/02 and QCH-APKT).
https://www.zccct-europe.com/en/new-products-for-spring-2023-presented-by-zcc-cutting-tools-europe/
Download Catalogue
2022
New Cutting Tool Products for increased productivity, reliability and accuracy.
High-Feed Milling Tools Applies High Feed Rates and Steep Ramping
The NuMaxHF line of new high-feed milling tools from Ingersoll Cutting Tools offers extreme ramping capabilities versus traditional high-feed milling tools. The thick, tangential insert features a diamond shape with a large inboard angle providing high feed rates and steep ramping angles.
https://www.shangintool.com/high-feed-milling.htm
HIGH-FEED MILLING - HOW IT WORKS?
Multi-Directional Turning Tool Maximizes Materials Removal
SuperTurnZ of Ingersoll Cutting Tools is an innovative system for multi-directional turning that utilizes the front and back cutting edge of a four-corner insert in a single tool.
https://www.moldmakingtechnology.com/products/multi-directional-turning-tool-maximizes-materials-removal
Ceramic High-Feeding Milling Line Highlights Extreme Roughing Performance
Ingersoll Cutting Tool’s CeraSFeed ceramic indexable high-feed line offers extreme roughing performance when milling heat-resistant super alloy (HRSA) materials.
Internal and Face Grooving Tools for Small Hole Diameters
Photo Credit: Sandvik Coromant
Sandvik Coromant has launched CoroCut QI, a range of internal and face grooving inserts designed for smaller diameters.
Carbide End Mills Developed for Micromachining Applications
Cutting tool manufacturer Guhring reports that its microtool offerings, including the RF100 Micro-Driver, are an answer to the challenges imposed by the creation of small or miniature molds.
Octagon Milling Cutter Delivers Maximum Process Reliability
Walter USA has introduced the Xtra-tec XT M5004 octagon milling cutter, a versatile milling tool that combines productivity with stability.
Closed-Pitch Solid Carbide Cutters Demonstrate Universal Finishing
Walter USA presents two multi-tooth solid carbide face milling cutters, the MC128 Advance and the MD128 Supreme, for finishing and semi-finishing, with a secondary use for dynamic milling.
https://www.moldmakingtechnology.com/products/closed-pitch-solid-carbide-cutters-demonstrate-universal-finishing
Grooving, Parting Off Insert Geometries Dedicated to Eliminating Vibrations, Increasing Insert Life
The Walter Cut DX18 double-edged grooving and parting off inserts with insert widths of 0.059-0.157" (1.5-4 mm) are the latest addition to Walter’s ever-expanding grooving product range
Solid Carbide Milling Cutters Tackle Difficult Applications Range
Walter USA has released two solid carbide milling cutters that successfully tackle titanium machining tasks: the MC377 Advance and the MD377 Supreme.
Indexable Thread Mill Demonstrates Universal Metal Cutting
Walter’s launched T2710 indexable thread mill is reported to bring higher levels of productivity, reliability and quality to the machining of short threads.
https://www.moldmakingtechnology.com/products/indexable-thread-mill-demonstrates-universal-metal-cutting
Exchangeable-Tip Drill Inserts Target Deep Hole Drilling in Low Carbon Steels
According to Walter USA, its P6006 insert for exchangeable-tip drills brings new levels of drilling efficiency to low carbon steels, structural steels and low alloy steels.
https://www.moldmakingtechnology.com/products/exchangeable-tip-drill-inserts-target-deep-hole-drilling-in-low-carbon-steels
Thread Formers Offer Enhanced Performance, Surface Finishes
Walter USA presents the TC420 Supreme thread for universal use. The HSS-E-PM thread former, with a high number of forming edges, produces high cutting speeds with up to 30% less torque, good surface finish and improved lubrication.
https://www.moldmakingtechnology.com/products/thread-formers-offer-enhanced-performance-surface-finishes
ER Collet System Features Anti-Friction Coating
Parlec, P3 ER collet system, the first coated ER collet system
https://www.moldmakingtechnology.com/products/er-collet-system-features-anti-friction-coating
Face Milling Platform Combines Multi-Corner Milling, High Feed Rates
YG-1’s FM10 PNMU face milling indexable inserts combine multi-corner face milling performance with high feed capabilities.
https://www.moldmakingtechnology.com/products/yg-1-launches-new-platform-of-cutters-and-inserts-2
Stainless Steel Turning Grade Expands Wear Resistance Capabilities
Tungaloy America’s AH6225 PVD grade insert for machining ISO-M stainless steels
https://www.moldmakingtechnology.com/products/stainless-steel-turning-grade-expands-wear-resistance-capabilities
Insert Geometries Expansion Provides More Cost-Efficient Steel Turning Solutions
Tungaloy America has expanded its ISO-EcoTurn turning insert line by adding 63 inserts in new geometries.
https://www.moldmakingtechnology.com/products/insert-geometries-expansion-provides-more-cost-efficient-steel-turning-solutions
2021
New cutting tools and machine tool accessories
Productivity Inc. is proud to offer new cutting tool technology and machine tool accessories to our customers, the instant that it is available.
RT100S Steel Machining Specialist
Stable and precise cutting edge geometry combined with ultra-fine surface in the cutting edge area.
Optimized cutting edge preparation
Specialized Geometry
Robust Carbide Grade
Ultimate Precision when Grinding
Vibration-damped boring bar in a variable exchangeable head system for turning
Advantages of the exchangeable head system with vibration- damped boring bar
In combination with vibration-damped boring bars, the concept of the boring bar with exchangeable cutting heads is particularly ideal for operations with long overhangs and a tendency for vibrations
Modular design: high variability, flexibility and versatility
Tool wear occurs mainly on the exchangeable cutting head; a holder therefore lasts longer Costs are minimised
All exchangeable cutting heads are equipped with high-performance cooling: highly efficient cooling of the cutting edges means longer tool lives
New TungHold ER Rubber Sealed Spring Collets
Designated with the highest grade AA
Enable higher precision gripping of round tools
Sizes ranging from ER11 to ER40
Ingersoll RhinoGroove - Optimized Parting and Grooving Line
Ingersoll RhinoGroove - Optimized Parting and Grooving Line
Single and double-ended inserts
Ideal for small component and shallow depth of cut parting & grooving
Vibration minimized due to the insert’s shorter length and improved center of gravity
30% lower price compared to longer parting & grooving inserts!
Optimized holder pocket design for better clamping
C type chip breaker features a frontal land for strength in general purpose applications
J type chip breaker has a positive cutting edge making it ideal for soft & gummy materials.
Three grade options (TT9080, TT7220 & TT8020) provide a solution for a wide variety of materials and applications
Kennametal Tangential Shoulder Milling
Mill 4-12KT requires up to 15% less horsepower, enabling increased feed rates, even on small machines.
Excellent floor finishes due to minimal axial runout.
With 7 grades, 7 corner radii, and depth-of-cut range up to .472″ (12mm), the program offers versatility to cover many shoulder milling applications.
New reCool® Coolant Retrofit
REGOFIX recool Product Shot
Converts existing tooling systems to thru coolant at low costs in 2 minutes
Speeds up to 6,000 rpm*
Coolant pressures up to 20 bar/290 PSI*
Maintenance free coolant lubricated bearings
* Higher speeds and coolant pressures available upon request.
Cutting Tools for Stainless Steels - Featuring the RT 100 VA drill
Guhring RT100VA Drill PhotoExtended tool life plus increased productivity
Specialized facet-style self-centering point geometry
New edge preparation technology creates ultra-precision cutting edge
Unique cutting edge and flute profile geometry
Nano-ATM heat and wear resistant PVD coating
You've Got to CNC this! The NEW One-Lok™ Single Station CNC Vise
You've Got to CNC this! The NEW One-Lok™ Single Station CNC Vise
BoltFast™ jaw system
Fixed jaw deflection virtually eliminated
Chip-free solid base
QwikSlide moveable jaw
Tungaloy DOFEED
High productivity with excellent chip evacuation and remarkable chip control
High feed per tooth up to 2 mm (0.079?)
Low cutting force design
Wiper insert for excellent surface finish at high feed rate, eliminating semi-finishing operation
Haimer Tool Dynamic TD Economic Balancing Machine
Tool Dynamic Economic balancing machine
One piece design
Perfect foundation for accurate measurements
Measures and compensates the unbalance in one plane
July 16, 2020
New Light Cutting Face Mill Increases Productivity in Low HP Machines - Tungaloy's TungEight-Mill face milling cutter.
The features are particularly effective when machining low carbon steel and stainless steel with chip breaking difficulty and tendency to smear.
Discover New Geometries Shaping Machining of Composites for Aerospace Productivity
Element Six, May 30 2019
https://www.azom.com/article.aspx?ArticleID=18086
Updated 22.7.2023, 11 Sep 2022, 11 Sep 2021, 11 August 2021
First published on 17 September 2020
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