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Productivity Improvement Through Machining Time Reduction and Machining Cost Reduction - Important Industrial Engineering Task.
Process improvement - What is machine time reduction? Man time reduction? Material usage reduction? Energy reduction? Information cost reduction?
The first president of ASME in his inaugural presidential address exhorted mechanical engineers to attention to the cost of reduction of machines and items produced through mechanical engineering design and production processes like cars.
The genius in F.W. Taylor resulted in proposing productivity improvement through machining time reduction (machine time reduction) and man time reduction as the core activity which will give cost reduction and income increase (to both employees and companies, this labor and capital).
Machining time reduction can be achieved by improving each of the elements that are used in machining. Taylor investigated each machine element - machine tools for power and rigidity, tool materials and tool geometry, work holding, use of coolant, cutting parameters (cutting speed, feed, depth of cut) and developed data and science for each element and increased productivity of machining. The framework laid by Taylor is followed even today and productivity improvement of machining is occurring.
TAYLOR (1906) - ELEMENTS AFFECTING CUTTING SPEED OF TOOLS IN THE ORDER OF THEIR RELATIVE IMPORTANCE
278 The cutting speed of a tool is directly dependent upon the following elements. The order in which the elements are given indicates their relative effect in modifying the cutting speed, and in order to compare them, we have written in each case figures which represent, broadly speaking, the ratio between the lower and higher limits of speed as affected by each element. These limits will be met with daily in machine shop practice.
279 (A) The quality of the metal which is to be cut; i.e., its hardness or other qualities which affect the cutting speed.
Proportion is as 1 in the case of semi-hardened steel or chilled iron to 100 in the case of very soft low carbon steel.
280 (B) The chemical composition of the steel from which the cutting tool is made, and the heat treatment of the tool.
Proportion is as 1 in tools made from tempered carbon steel to 7 in the best high speed tools.
281 (C) The thickness of the shaving; or, the thickness of the spiral strip or band of metal which is to be removed by the tool, measured while the metal retains its original density; not the thickness of the actual shaving, the metal of which has become partly disintegrated.
Proportion is as 1 with thickness of shaving 3/16 of an inch to 3.5 with thickness of shaving 1/64 of an inch.
282 (D) The shape or contour of the cutting edge of the tool, chiefly because of the effect which it has upon the thickness of the shaving.
Proportion is as 1 in a thread tool to 6 in a broad nosed cutting tool. ,
283 (E) Whether a copious stream of water or other cooling medium is used on the tool.
Proportion is as 1 for tool running dry to 1.41 for tool cooled by a copious stream of water.
284 (F) The depth of the cut; or, one-half of the amount by which the forging or casting is being reduced in diameter in turning.
Proportion is as 1 with 1/2 inch depth of cut to 1.36 with 1/8 inch depth of cut.
285 (G) The duration of the cut; i. c., the time which a tool must last under pressure of the shaving without being reground.
Proportion is as 1 when tool is to be ground every 1.5 hour to 1.207 when tool is to be ground every 20 minutes.
286 (H) The lip and clearance angles of the tool.
Proportion is as 1 with lip angle of 68 degrees to 1.023 with lip angle of 61 degrees.
287 (J) The elasticity of the work and of the tool on account of producing chatter.
Proportion is as 1 with tool chattering to 1.15 with tool running smoothly.
288 A brief recapitulation of these elements is as follows:
(A) quality of metal to be cut: 1 to 100;
(B) chemical composition of tool steel: 1 to 7;
(C) thickness of shaving: 1 to 3.5;
(D) shape or contour of cutting edge: 1 to 6;
(E) copious stream of water on the tool: 1 to 1.41;
(F) depth of cut: 1 with 1/2 inch depth to 1.36 with 1/8 inch depth of cut;
(G) duration of cut: 1 with 1.5 hour cut to 1.20 with 20-minute cut;
(H) lip and clearance angles: 1 with lip angle 68 degrees to 1.023 with lip angle of 61 degrees;
(J) elasticity of the work and of the tool: 1 with tool chattering to 1.15, with tool running smoothly.
Taylor's machining time reduction is given the name "Time Study." Time study became a principal technique of Industrial Engineering. But in the evolution of the discipline and profession, overtime, the s focus on study of man's work increased and time study became a subject or method that develops the standard time prescription for the method developed using method study. Method study also focused on manual work only primarily. A subject named "Work Study," a combination of method study and time study or work measurement became popular. Machine work based industrial engineering slow disappeared from industrial engineering. Professor Narayana Rao, brought the focus on machine back in industrial engineering by proposing "machine work study" as an important area in productivity improvement and industrial engineering. Machine based industrial engineering is part of Toyota Production System and was described by Shigeo Shingo in his book. Jidoka, a pillar of TPS, also is interpreted as machines that do not produce waste which indicates machine based productivity improvement. Machine work study involves evaluating each element of machine work with the current possible best practice, improving it appropriately and integrating all the elements to give the highest productivity, lower cost or lowest time. Element level improvement and integrating elements to get the best system improvement has to occur one after another in industrial engineering. Element level thinking and holistic thinking both have to take place in productivity improvement.
To do machine work study, industrial engineers required the basic knowledge and awareness of periodic developments in machine tool and cutting tool engineering and process planning. Productivity science discovers and codifies variables that have an effect on productivity. Industrial engineers have to combine productivity science with knowledge of machine tools and process planning to do productivity engineering.
Taylor's Contribution to Machining Time Reduction and Machining Science/Productivity Science
The first scientific studies of metal cutting were power requirements for various operations so that steam engines of appropriate size could be selected for tools. A number of researchers constructed crude dynamometers and conducted systematic experiments to measure cutting forces. The best known was E. Hartig, whose 1873 book was a standard reference on the subject for many years. Development of more advanced dynamometers occupied researchers after Hartig's book was published. In addition, several studies of the mechanism of chip formation were carried out, most notably by Time, Tresca, and Mallock. By carefully examining chips, these researchers recognized that chip formation was a shearing process.
In 1868 Robert Mushet, an English steel maker, developed an improved tool steel. It was a Tungsten alloy which proved to be self hardening. Mushet took extraordinary measures to prevent the theft of his recipe and the process he used is unknown to this day. The material was superior to carbon steel for cutting tools and was widely used in both Europe and America.
The great historical figure in the field of metal cutting, Frederick W. Taylor, was active at the end of the nineteenth century. Taylor became more famous as the founder of scientific management, and many books on scientific management do not mention his work in metal cutting. The metal cutting work, however, was crucial to the implementation of his productivity engineering and management theories. Books on machining still mention Taylor and his contribution to metal cutting theory.
As foreman of the machine shop, Taylor felt that shop productivity could be greatly increased if a quantitative understanding of the relation between speeds, feeds, tool geometries, and machining performance can be established and the right combination of cutting parameters are specified by managers and used by machinists. Taylor embarked on a series of methodical experiments to gather the data necessary to develop this understanding. The experiments continued over a number of years at Midvale and the nearby Bethlehem Steel Works, where he worked jointly with metallurgist Maunsel White. As a result of these experiments, Taylor was able to increase machine shop productivity at Midvale by hundred percent even though in certain individual jobs and machines, productivity increases was as much as a factor of five. One of Taylor's important practical contributions was his invention of high speed steel, a cutting tool material. The material permitted doubling of cutting speed, which in turn permitted doubling spindle speed for the same diameter of the work and thereby increase in feed which reduced machining time.
Taylor also established that the power required to feed the tool could equal the power required to drive the spindle, especially when worn tools were used. Machine tools of the day were underpowered in the feed direction, and he had to modify all the machines at the Midvale plant to eliminate this flaw. He also demonstrated the value of coolants in metal cutting and fitted his machines with recirculating fluid systems fed from a central pump. Finally, he developed a special slide rule for determining feeds and speeds for various materials.
Taylor summarized his research results in the landmark paper On the Art of Cutting Metals, which was published in the ASME Transactions in 1907. The results were based on 50,000 cutting tests conducted over a period of 26 years. Taylor's also indicated the importance of tool temperatures in tool life and developed the famous tool life equation. His writings clearly indicate that he was most interested in efficiency and economy in his experiments and writings.
Machine tools built after 1900 utilized Taylor's discoveries and inventions. They were designed to run at much higher speeds to take advantage of high speed steel tools. This required the use hardened steel gears, improved bearings and improved bearing lubrication systems. They were fitted with more powerful motors and feed drives and with recirculating coolant systems.
The automotive industry had become the largest market for machine tools by World War I and it has consequently had a great influence on machine tool design. Due to accuracy requirements grinding machines were particularly critical, and a number of specialized machines were developed for specific operations. Engine manufacture also required rapid production of flat surfaces, leading to the development of flat milling and broaching machines in place of shapers and planers. The development of the automobile also greatly improved gear design and manufacture, and machine tools were soon fitted with quick-change gearing systems. The automotive industry also encouraged the development of dedicated or single purpose tools. Early examples included crankshaft grinding machines and large gear cutting machines. It led to the development of transfer machine. An in-line transfer machine typically consists of roughly thirty highly specialized tools (or stations) connected by an automated materials handling system for moving parts between stations. The first was built at Henry Ford's Model T plant in Detroit. . Transfer machines required very large capital investments but the cost per piece was lower than for general purpose machines for the production volumes of hundreds of thousands required in auto industry.
In the 1930's a German company introduced sintered tungsten carbide cutting tools, first in brazed form and later as a detachable insert. This material is superior to high speed steel for general purpose machining and has become the industry standard.
A great deal of research in metal cutting has been conducted since 1900. A bibliography of work published prior to 1943 was compiled by Boston, Shaw and King. The shear plane theory of metal cutting was developed by Ernst and Merchant and provided a physical understanding of cutting processes which was at least qualitatively accurate for many conditions. Trigger and Chao and Loewen and Shaw developed accurate steady-state models for cutting temperatures. A number of researchers studied the dynamic stability of machine tools, which had become an issue as cutting speeds had increased. This resulted in the development of a fairly complete linear theory of machine tool vibrations. Research in all of these areas continues to this day, particularly numerical analysis work made possible by advances in computing. All these discoveries and their implementation in machine tools gives higher productivity in machining.
One of the most important innovations in machine tools was the introduction of numerical control. Today CNC machine tools are the most used ones.
New tool materials were invented. A variety of ceramics are currently used for cutting tools, especially for hardened or difficult-to-machine work materials. Ceramic and diamond tools have replaced carbides in a number of high volume applications, especially in the automotive industry. Carbides (often coated with ceramic layers) have remained the tool of choice for general purpose machining. There has been a proliferation of grades and coatings available for all materials, with each grade containing additives to increase chemical stability in a relatively narrow range of operating conditions. For many work materials cutting speeds are currently limited by spindle and material handling limitations rather than tool material considerations. Dozens of insert shapes with hundreds of integral chip breaking patterns are available now.
Chapter 13. Machining Economics and Optimization
in Metal Cutting Theory and Practice - Stephenson - Agapiou, 2nd Edition
Economic Considerations are important in designing the machining process of a component. Each operation done on a machine involved number of decisions. There is more than one approach for doing an operation and each approach will have as associated machining time, part quality and cost of machining. An effective and efficient methodology is to be employed to attain the specified quality of the operation with the least cost. The machining cost of an operation on a component is made of several components. They include machine cost, tool cost, tool change cost (includes set up), handling cost, coolant cost etc. Some of these costs vary significantly with the cutting speed is different directions. At a certain cutting speed we get the minimum cost and at certain other cutting speed we get the least machining time. There is a need to calculate these minimum point cutting speeds for each work material, tool material and machine tool combinations. F.W. Taylor developed slide rules for this purpose. Now those slide rules are not in place, but machining handbooks and machine tool/cutting tool manufacturers provide guidance. Process planners and industrial engineers need to do the required calculations depending on the trial production within their plans. Time Estimates Required Total Production Time for an Operation, TTO =
Tm + (Tm/Tl)Tlul + Tcs + Te + Tr + Tp + Ta + Td + Tx)
Where
TTO = Total Production Time for an Operation
Tm = Cutting time
Tl = Tool life
Tlul = Tool unloading and time
Tcs = Tool interchange time
Te = Magazine travelling time
Tr = Approach time
Tp = Table index time
Ta = Acceleration time
Td = Deceleration time
Tx = Tool rapid travel time
Time study used for machine work study has to determine these time times from formulas as well as time study observations for the existing way and proposed way to validate the time reduced by the operation analysis based on operation study and time data.
Constraints for Minimizing the Machining Time - Cost
Allowable maximum cutting force, cutting temperature, depth of cut, spindle speed, feed, machine power, vibration and chatter limits, and party quality requirement.
Industrial engineers must have knowledge of maximum permissible depth of cut, feed and cutting speed.
Industrial engineers have to monitor research and continuously update their understanding of limit to the constraints. Developments in engineering and industrial engineering keep increasing the quantity of limits in favor of more productivity.
Companies expect efficiency gains of a total of 12% over five years. Cost reduction due to automation, better asset utilization and lower quality cost will contribute to efficiency gains.
Source: Digital Factories 2020: Shaping the future of manufacturing
PWC.de report 2017
The top management is to set productivity objectives and goals that are in line with and integrated into organisation’s long-term strategic plans. To ensure that these goals are met, key performance indicators and targets need to be identified and developed. The organisation’s productivity performance can be monitored against these targets.
Phase I – Diagnose
For any productivity intervention to be effective, management should have a thorough understanding of the organisation’s current situation. This can be done through a productivity diagnosis.
A productivity diagnosis covers a qualitative assessment of organisation’s performance in relation to the productivity levers and a quantitative assessment of organisation’s performance based on certain key indicators that are linked to the various productivity levers.
These assessments are undertaken specifically to:
Measure the gap between the current situation and the productivity goals set by the organisation in the past.
Identify organisation’s strengths and weaknesses in the area of productivity improvement.
Determine the underlying causes of the gaps (for the weak areas).
Determine areas for improvement.
Qualitative Assessment of Performance
The key levers that affect productivity can be identified.
Technology - Adoption on appropriate technology on a continuing basis
Machinery & Equipment - Selection of appropriate machinery and equipment and their replacement based on engineering economic analysis
Operators - Human effort engineering - Design manual activities incorporating motion studies, principles of motion economy and ergonomics
Productivity Levers
Reduction of Price and Reduction of External Failure of Products - Stimulate Demand providing market for increased productivity and economies of scale.
Increasing Skills of Operators and Managers - Productivity Training
Changing Attitudes of Operators and Managers
These levers are areas or actions that an organisation can focus on to improve productivity significantly.
Productivity levers do not operate in silos. Improvements made to one lever require complementary actions on some other levers, for it to be effective. For example, the adoption of new technology inevitably requires the complementary actions of training of employees and redesign of work processes. Similarly, weakness in one lever is likely to have an adverse effect on other levers.
Quantitative Assessment of Performance
There are 10 common indicators used to gauge an organisation’s productivity performance:
Labour productivity
Sales per employee
Value added-to-sales ratio
Capital productivity
Sales per dollar of capital
Capital intensity
Labour cost competitiveness
Labour cost per employee
Profit-to-value added ratio
Profit margin
Along with an analysis of organisation’s overall performance, the performance of the operational units and functions also needs to be measured.
To know how well an organisation is faring in the area productivity, a comparison the organisation’s performance against some standard has to be made. This can be done across time and space, with external entities (e.g. benchmarks and organisations within the same industry) and within the organisation (e.g. between departments for setting departmental goals) . Such comparisons provide valuable information on the organisation’s relative standing vis-à-vis competitors and the best-in-class performers.
Organisations who want to assess themselves against their competitors can use the Inter-firm Comparison (IFC) tool. Some industry organizations conduct IFC studies involve comparing productivity ratios of organisations in the same industry. Their identities are kept confidential and summary results are circulated or sold as reports to the members of the industry organization.
Phase II
Develop Road Map
After the diagnosis is completed, a productivity road map or action plan has to be developed. The road map indicates specific activities to achieve productivity goals in a coordinated and systematic manner.
Components of Productivity Road Map
A productivity road map addresses the following:
What affects productivity?
Identify the specific actions that need to be taken in relation to the findings from the diagnosis.
Spell out the key performance indicators, targets and deliverables for the actions to be taken.
Who affects productivity?
Identify the units or individuals who will carry out the actions.
Assign responsibilities and accountabilities to the parties identified.
When are the activities to be undertaken?
Set milestones and timelines for the actions to be taken.
The actions should then be taken and monitored according to the road map.
Read David Sumanth's discussion of productivity planning.
Sumanth, D. J., & Yavuz, F. P. (1984). A formal approach to productivity planning in companies. Engineering Management International, 2(4), 219-227. https://doi.org/10.1016/0167-5419(84)90043-7
Framework for Systematic Design of Productivity Strategies
In the proceedings
Advances in Ergonomics of Manufacturing: Managing the Enterprise of the Future: Proceedings of the AHFE 2017 International Conference on Human Aspects of Advanced Manufacturing, July 17-21, 2017, The Westin Bonaventure Hotel, Los Angeles, California, USA
Industrial Engineering is Continuous Improvement of Processes Having Engineering Operations/Processes
Industrial engineers have to use every pathway available for productivity improvement. Industrial engineering is engineering based in operations or shop floor and it is also continuous engineering improvement of the product and process first and then improvement of related process elements like planning, communication (information), inventory etc.
In machine shop industrial engineering or industrial engineering of machining processes and machining operations, simulation of machining process is also an important path to understand the process to increase productivity by reducing the cycle time by modifying the machining parameters or variables. Industrial engineers need to have knowledge of machine simulation and use it appropriately in productivity improvement.
Machining Process Analysis Using Simulation and Finite Element Models
"Machining Process Analysis" is the chapter name used by the authors Stephenson and Agapiou to discuss this topic. According to them, three types of analyses of process are performed. One is force, power, and cycle time analyses using kinematic simulations (or mechanistic models). Second is, structural analysis for clamping and fixturing using finite element methods. The third is the detailed chip formation analyses done using finite element models.
Kinematic simulations of machining processes are used to calculate cycle times and time histories of cutting forces and power. The inputs required include the part and tool geometries, tool paths, and cutting pressures for the combination of "tool–workpiece material" of interest, which may be measured in tests or estimated from finite element calculations. The tool geometries and tool paths are preferably read directly from CAD and CAM systems. Based on this information, the kinematic motions of the tool with respect to the workpiece as a function of time can be simulated, and the instantaneous area of material being cut (the interference between the tool and workpiece) at any time can be computed from the tool path and part geometry.
Commercial programs for kinematic simulation include Third Wave Systems’ Production Module programs and MillSim from Manufacturing Laboratories, Inc..
Structural finite element analysis clamping and fixturing is used to estimate workpiece distortions due to clamping and machining. The objective of the analysis is to minimize such distortions for critical features, which may be accomplished by stiffening the part or fixture in directions of heavy loading, modifying the tool path or cutter geometry to direct forces in stiff or noncritical directions, choosing clamping and locating schemes, which minimize clamping distortion and support compliant portions of the part, and minimizing clamping forces. Finite element analysis permits a wider variety of options to be investigated more quickly and cheaply than through prototype part and fixture tests.
Kinematic Simulations of Machining Processes - Applications
TURNING
Turning is easy to simulate because the geometry and kinematic motions of the tool and workpiece are easily described. When turning large volumes of parts on CNC lathes, simulation helps to reduce cycles times and thus the number of machines and capital investment required.
Cutting forces are calculated by multiplying measured cutting pressures by the calculated uncut chip area. Various formulas are available to calculate many variables required or simulation.
Commercial programs for kinematic simulation include Third Wave Systems’ Production Module programs and MillSim from Manufacturing Laboratories, Inc..
Third Wave - PRODUCTION MODULE
TOOLPATH LEVEL ANALYSIS AND OPTIMIZATION
Modern manufacturing requires continuous improvements to adapt and grow in rapidly changing markets.
Production Module is the premier CAE product for modeling machining at the toolpath level. Production Module integrates advanced, experimentally validated, FEA driven material models, with CAD/CAM into an easy to use system for analyzing and improving machining processes. This gives engineers more information than trial-and-error testing, enabling Bold Innovation.
We bring together cutting-edge technology, innovative software, and expert training to help businesses achieve maximum efficiency and profitability in their machining operations.
FINITE ELEMENT ANALYSIS FOR CLAMPING, FIXTURING, AND WORKPIECE DISTORTION APPLICATIONS
Structural finite element analysis can be used to estimate workpiece distortions due to both clamping
and machining forces.
For analyzing clamping distortions, the inputs required are the clamping and locating points and the clamping forces. Finite element models of both the part and fixture structure are required; attempts to replace the fixture with equivalent boundary conditions, such as springs or displacement constraints, save computing time but generally yield less accurate results. The part finite element model used for structural design is usually adequate, although some mesh refinement near the clamping points may be needed. If a fixture model is not available, one must be created for the support and clamping elements in contact with the part. The interfaces between the part and fixture should be modeled using contact elements with friction for optimum accuracy. A static analysis in which the clamping loads are applied at the clamping points yields a distortion prediction. The major unknowns are usually the friction coefficients at the contact points; these can be determined experimentally if the solution is sensitive to these variables. In overconstrained clamping schemes (i.e., for four-point locating schemes on planes), locator dimensional variations are also significant. This type of analysis is most often used for thin-walled, compliant parts; in this case it is rarely necessary to model additional elements of the machine tool structure.
When modeling distortions induced by machining forces, more elements of the system must generally be considered. The machining forces act between the tool and part, and may cause deflections of two broad structural assemblies: the tool, toolholder, and machine tool structure on one side, and the part and fixture on the other. To compute deflections, cutting force histories must be estimated, often using the kinematic simulations, and applied to structural finite element models of both assemblies. In some operations, however, the compliance of one element of the system (tool/toolholder/machine structure or part/fixture) may be much larger than the other, so that the other element can be treated as rigid. Sequential or iterative analyses may be required in applications in which machining significantly changes the structural compliance of the part or in which cutting force and deflections are coupled.
Jishuken, pronounced "jee-shoo-ken", is a Japanese term translating to "self-learning" or "autonomous study groups". It's a key element of the Toyota Production System (TPS) and a powerful tool for driving continuous improvement within an organization. Unlike other Kaizen activities that might have broader objectives, Jishuken focuses on solving complex, critical issues and developing leadership capabilities at the same time.
Key aspects of a Jishuken event
Problem Identification and Scope Definition: Jishuken starts with identifying a specific problem or area requiring improvement, often driven by management or triggered by abnormal conditions.
Team Formation: A small, cross-functional team, typically comprising managers and senior managers (5-7 members), is assembled to address the chosen problem. The team may also include individuals from relevant departments or even a facilitator from outside the organization.
Data Collection and Analysis: Team members gather relevant data to understand the current situation and the extent of the problem. This might involve techniques like Gemba walks (visiting the actual worksite), interviews, surveys, and process mapping.
Root Cause Analysis: Using tools like Fishbone diagrams or the 5 Whys technique, the team delves into the collected data to pinpoint the underlying causes of the problem.
Solution Generation and Implementation: Based on the root cause analysis, the team brainstorms potential solutions, prioritizes them, and develops a plan for implementing the most impactful ones. Pilot testing is often employed before wider rollout.
Evaluation and Standardization: After implementation, the team evaluates the effectiveness of the changes using key performance indicators (KPIs) and data tracking. If the changes prove successful, they are standardized, documented in Standard Operating Procedures (SOPs), and shared across the organization.
Benefits of Jishuken
Leadership Development: Jishuken provides a practical training ground for managers to develop their TPS skills, learn problem-solving techniques, and improve their ability to coach and teach others.
Deepened Understanding of TPS: Through hands-on application and interaction with different levels of the organization, managers gain a more profound understanding of TPS principles and how to implement them effectively.
Sustainable Improvement: By focusing on root cause analysis and addressing issues at the source, Jishuken helps drive long-term, sustainable improvements rather than quick fixes.
Improved Quality and Efficiency: Jishuken efforts can lead to significant improvements in various areas like reducing defects, optimizing processes, and enhancing efficiency.
Fostering a Culture of Continuous Improvement: By empowering employees and promoting teamwork, Jishuken helps embed a culture of continuous improvement and problem-solving within the organization.
Jishuken in the Toyota Production System
Toyota uses Jishuken as a management-directed Kaizen activity to identify areas needing continuous improvement and to spread Kaizen principles throughout the organization. It's a proactive approach that encourages managers to take ownership of their processes and continuously seek opportunities for improvement.
In essence
Jishuken is more than just a problem-solving event; it's a strategic approach to developing leadership capabilities, fostering a culture of continuous improvement, and ultimately strengthening the organization as a whole.
There is one more article in my blog on Jishuken by Isao Kato in draft form.
LLM Initiated
Jishuken: a management-driven approach to continuous improvement
Jishuken, Part Two: The Power of Self-Learning - Lean ...
Kaizen Workshop - Lean Enterprise Institute
All You Need To Know About Jinshuken
Reclaiming the Toyota Production System through Lean TPS ...
Developer Productivity Engineering (DPE) is a software development practice used by leading software development organizations to maximize developer productivity and happiness.
Developer Productivity Engineering Overview
As its name implies, DPE takes an engineering approach to improving developer productivity. As such, it relies on automation, actionable data, and acceleration technologies to deliver measurable outcomes like faster feedback cycles and reduced mean-time-to-resolution (MTTR) for build and test failures. As a result, DPE has quickly become a proven practice that delivers a hard ROI with little resistance to product acceptance and usage.
Organizations successfully apply the practice of DPE to achieve their strategic business objectives such as reducing time to market, increasing product and service quality, minimizing operational costs, and recruiting and retaining talent by investing in developer happiness and providing a highly satisfying developer experience. DPE accomplishes this with processes and tools that gracefully scale to accommodate ever-growing codebases.
Gradle is pioneering the practice of DPE and Gradle Enterprise serves as the key enabling technology and solution platform.
METR’s study on how AI affects developer productivity.
Abi Noda
July 24, 2025
Conducted by METR, a nonprofit research organization focused on evaluating AI capabilities, the study found that AI tools actually slowed down developers working on real-world tasks. (Read the full paper here, and METR’s blog post here.)
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.
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
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
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 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/
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
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.
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
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
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/
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
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
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/
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
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
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.
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.
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.
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.
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.
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.
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
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
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
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. ..
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.
A Detailed Review on Design and Development of Fixture for ...
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Design and Analysis of Milling Fixture for HMC - Krishi Sanskriti
www.krishisanskriti.org › vol_image
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by VS Warule - Cited by 2 - Related articles
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
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milling fixtures - Open Source Machine Tools
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Article: Conceptual design and development of pneumatically ...
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by S Gothwal - 2018 - Cited by 4 - Related articles
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Design and Manufacturing of 8 Cylinder Hydraulic Fixture for ...
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by CM Patel - 2014 - Cited by 7 - Related articles
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Improving Machining Productivity of Single Cylinder Engine ...www.ripublication.com › ijaer18
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Maximum performance and productivity with the large milling machine W 250 XF
World première of the most powerful cold milling machine at Bauma
With the new W 250 XF, Wirtgen presents a machine that impresses with high milling performance and simultaneously low specific emissions. It is now available in the USA, Australia, Europe, Japan and Taiwan.
Its dual-engine drive system is controlled by MILL ASSIST to ensure maximum performance.
