FlowXpert 2015, Flow International Corp.’s upgrade to its FlowXpert software suite, offers new capabilities for 3D pathing LNMU Insert and cutting to enable waterjet users to work more effectively in 3D with less complexity. The CAD/CAM software platform expands on the company’s FlowMaster intelligent software suite and includes Design powered by Spaceclaim, an integrated 3D CAD/CAM programming tool with Flow Sequencer. This integration, engineered in partnership with Spaceclaim, increases flexibility and is specifically designed for waterjet cutting, enabling faster waterjet programing. According to Flow, best practices such as waterjet application tips, material cut speed knowledge, improved pathing algorithms and expanded lead in/out customization enables the program to estimate what steps are needed to produce the best part.
The software includes a redesigned interface for 2D and 3D part programming. Users are able to design a part and path VCMT Insert it in the same program, and it is possible to modify the geometry of a part without losing the path. In most cases, the Sequencer integration will automatically update the path to accommodate the changes, the company says. Additionally, the software detects model and path errors and suggests corrections. Additional features include 3D CAM offset capabilities, versatile sheet metal processing from Spaceclaim, customizable clean-up tools and the capability to save a 3D model as a 2D programmed part.
The Carbide Inserts Website: https://www.cuttinginsert.com/product/cnmg-turning-insert/
When a business relies on being able to design and build custom products, it needs to be able to count on the quality and support of its manufacturing equipment. When one or both of these factors doesn’t live up to expectations, production can come to a complete standstill. Quality Machine in Bridgeport, West Virginia encountered this very problem. Programming inefficiencies and subsequent poor cut quality from its existing plasma cutter hampered the company’s ability to effectively produce its full range of products. By integrating Hypertherm’s plasma-cutting system and software into the manufacturing process, Quality Machine was able to improve cut quality and save both time and money.
The third-generation job shop was founded in 1975 as a service provider for the surface mining industry. It specializes in customized products, such as oilfield units and hydraulic systems for the oil and gas industry. The company has also expanded into a parts business, focusing on large, custom and proprietary jobs producing oil and gas booms, skidded- and trailer-mounted oilfield units, Marcellus Shale fracturing fluid systems, and Hardox extreme-duty buckets.
As a Hardox Wearparts distributor, Quality Machine needs to make high-quality parts at the fastest possible speeds, says Christian Marsh, business manager and safety director. “We have to be able to cut custom-designed parts on the spot. Good plasma cut quality on the holes is especially important because it saves us time and money,” he says. If a hole for a pin or bolt cannot be plasma cut to quality standards, it has to be drilled or punched, which takes more time. To complicate this matter, the Hardox parts are not easily drilled and they cannot be punched due to the material’s high tensile strength.
More production difficulties arose from ineffective integration of plasma equipment components and lack of support from a variety of suppliers. For example, Mr. Marsh says that when there was a problem with the plasma cutter, blame was passed down the line from the OEM, to the software company, to the installers, until the cycle started again. “It was a mess that left us with very little help,” he says. Beyond that, its plasma cutter was supposed to be capable of scribing part numbers and bend lines to ease layout prior to bending on a press brake, but Mr. Marsh says that never worked right.
In search of a way to improve cut quality, the company considered waterjet. However, concerns about operating costs, garnet hassle and higher maintenance costs made the company look for an alternate solution. It began to investigate the recent advancements in plasma cutting and sought help from Hanover, New Hampshire-based cutting machine manufacturer Hypertherm. Quality Machine needed a solution that included efficient nesting software too, because the nesting software on its old plasma cutter was not communicating properly with the unit. In addition, it needed a cutter that could offer precise motion to improve cut quality and overall Cemented Carbide Inserts productivity. The company ultimately adopted Hypertherm’s True Hole technology, which combines a HyPerformance plasma HPR400XD, an EdgePro CNC, ArcGlide torch height control and ProNest 2010 software. By purchasing all of the plasma-cutting components from a single manufacturer, Quality Machine was able to eliminate its previous support issues.
The new plasma system immediately improved hole quality, Mr. Marsh says. The previous unit cut holes that were oblong and tapered. For example, when attempting to cut a 1-inch-diameter hole clearance for a 7/8-inch-diameter bolt, the old machine would cut a 1-inch diameter at the top and a 3/4-inch by 1/2-inch oval at the bottom, thus making the sides of the hole tapered. A 7/8-inch bolt would not be able to fit in that hole, Mr. Marsh says.
True Hole technology is CCMT Insert automatically applied by the nesting software package and CNC. A specific combination of parameter settings, such as process gas selection, gas flow rates, pierce and lead-in/lead-out techniques, cut speeds, and cut timing are automatically applied and optimized for mild steel hole quality by specific amperage, material thickness and hole size. For example, after a part model is created in CAD, it is imported into ProNest 2010 where holes are automatically recognized. Machine code is modified to optimize the parameters mentioned above, and all other variables are automatically set to optimize cut quality. One important parameter that is set is the automatic switching from O2/air for the contour cut to O2/O2 for the holes and then back to O2/air to continue finishing the cut. In mild steel applications, True Hole technology can improve cylindricity by as much as 50 percent when compared to common plasma systems, Hypertherm says.
On average, ProNest 2010 has helped Quality Machine increase its productivity by 33 percent, Mr. Marsh explains. The Hardox parts are no longer cut with negative angles and consumables last 30 percent longer. Now, all Hardox parts are cut with the Hypertherm HPR400XD to ensure cut quality. “We wanted everything to work together seamlessly, and the software capability alone is leaps and bounds above what we had before, so our efficiency has improved,” Mr. Marsh says.
The Carbide Inserts Website: https://www.cuttinginsert.com/product/vcgt-insert/
Monitoring tool wear and estimating tool life when using CBN inserts is crucial for maintaining machining efficiency and preventing unexpected tool failures. Several common methods and techniques are employed for this purpose:
Visual Inspection: Regular visual inspection of the CBN insert can provide initial indications of wear. TCMT Insert Look for signs of flank wear (wear on the side of the insert), crater wear (wear on the cutting edge), and chipping. Operators can use magnifying tools or digital microscopes for a more detailed examination.
Tool Life Charts: Tool manufacturers often provide tool life charts or recommendations based on their insert grades and machining conditions. These charts offer estimated tool life under specific cutting parameters, aiding in tool life estimation.
Cutting Force Monitoring: Monitoring cutting forces during machining can help detect changes in tool wear. As a tool wears, it may require more cutting force to maintain the same material removal rate. Force sensors or dynamometers are used for this purpose.
Vibration Analysis: Monitoring vibration levels SNMU Insert during machining can reveal irregularities caused by tool wear. Increased vibration may suggest that the insert needs replacement.
Tool Life Testing: Conducting controlled tests where tool inserts are used until failure or a predetermined wear level is reached can provide valuable data for estimating tool life in specific applications.
The choice of tool wear monitoring method depends on the machining process, equipment available, and the level of precision and automation required. Combining multiple monitoring methods can provide a more comprehensive view of tool wear and tool life, helping to optimize tool change intervals and reduce production downtime.
Single-flute carbide end mills are cutting tools primarily used in machining and milling operations. They are known for their efficiency and precision in certain applications. These end mills are typically used for machining various materials, and the choice of material depends on the specific requirements of the job. Here's a breakdown of the materials often machined with single-flute carbide end mills and the reasons for their use:
Plastics:
Materials: Common plastics like acrylic, PVC, and HDPE.
Reason: Single-flute carbide end mills are suitable for plastics due to their low cutting forces and reduced chip load. The CNMG Insert single flute design helps prevent chip clogging and provides better chip evacuation in softer materials.
Soft Metals:
Materials: Aluminum, brass, and copper.
Reason: These end mills are effective for soft metals because they can achieve high cutting speeds without causing excessive heat buildup. The single flute design aids in chip clearance, and carbide construction provides durability and wear resistance.
Wood:
Materials: Various types of wood, including hardwoods and softwoods.
Reason: Single-flute carbide end mills work well with wood because they create clean cuts with minimal tear-out. The single flute helps with chip evacuation and reduces the chances of wood fibers getting caught in the cutting edge.
Composites:
Materials: Fiberglass, carbon fiber, and other composite materials.
Reason: Single-flute carbide end mills are suitable for composites because they minimize delamination and provide precise cuts. The single flute design reduces the chances of fiber pullout and prevents the material from overheating.
Thermoplastics:
Materials: Materials like nylon and Teflon.
Reason: Single-flute end mills are effective in machining thermoplastics due to their low friction and reduced heat generation. This helps prevent material deformation or melting during cutting.
Non-ferrous Materials:
Materials: Non-ferrous materials like bronze and zinc.
Reason: Single-flute carbide end mills are commonly used for non-ferrous materials because they can achieve high material removal rates without causing excessive tool wear.
Soft Steels:
Materials: Mild steel and low-carbon steel.
Reason: While not as common as other materials, single-flute carbide end mills can be used for soft steels when high precision is required. The single flute design helps maintain tool stability.
It's important to note that the choice of end mill and machining parameters (e.g., cutting speed, feed rate, depth of cut) should always be based on the specific material being machined, the desired surface finish, and the machine's capabilities. Single-flute carbide end mills are valued for their ability to reduce chatter and produce fine finishes in materials with low machinability, but they may not be suitable for all applications or materials.
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The Carbide Inserts Website: https://www.cuttinginsert.com/product/sdmt-insert/
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