Chip Removal Chamber of Horrors
This case history from Mastercam is appropriately themed for Halloween.
Fiendishly fast CNC cutting created this “chamber of horrors,” which is not such a bad problem to have after all.
This case history from Mastercam/CNC Software Inc. is appropriately themed for Halloween:
Any sorcerer will tell you that ghoulish consequences may result for those who do not heed the admonishments of technology wizards and other magical advisors. A case in point is the recent experience of Planet Tool & Engineering (O'Fallon, Missouri).
The company wanted to explore the benefits of using Mastercam tool paths incorporating Dynamic Motion technology for high-speed roughing of aerospace components and other parts. The technology adjusts tool motions in accordance with material conditions ahead of the tool to maintain a constant chip load. It makes it possible to machine rapidly at stepovers of 50 percent or less with deep (frequently full-flute) engagement of the end mill. It’s almost spooky!
Engineers at the Planet Tool & Engineering divined that there could be multiple treats associated with this approach, including faster programming, reduced tool wear and dramatically higher material removal rates (up to 70 percent).
There was also an annoying trick that might materialize should programmers like Chris Branco ignore sage advice from Jeff Kleinheider of Mastercam reseller QTE Manufacturing Solutions: His machine could be cutting, as if possessed by a demon, at a pace with which its chip-removal system could not contend.
Alas, this prophecy came to pass. Mr. Branco ignored the warning and went forward programming one of the first parts, an aluminum enclosure for aerospace electronics, at the highest possible material removal rates based on the cutting tool vendor’s chipload recommendations. The photo above is a reminder of what happens with you disregard your CAM software vendor's warnings. The offending chip-removal system must now be exorcised, or replaced entirely.
To read about another shop’s success with Mastercam Dynamic Motion, click here.
Related Content
-
TTI Brings Specialty Gear Production In-House with Multiaxis Machining
By investing in a 3+2-axis machine and utilizing simulation software for diagnostic checks, Techtronic Industries turned a four- to ten-week lead time into a one- to two-week lead time.
-
Building A Powerful Bridge from the CAM Programmer to the Shop Floor Operator
SolidCAM for Operators provides a powerful bridge from CAM programming to the shop floor to best streamline the machine shop process with its CAM part simulation. It provides a clear picture to the operator for setup and prove-out, enables minor G-Code changes and avoids crashes, broken tools and scrapped parts.
-
IMTS Takeaways From the Modern Machine Shop Editorial Team
The first in-person IMTS in four years left the MMS editorial staff with a lot to digest. Here are a few of our takeaways from the show floor.