How to Achieve High Productivity Manufacturing
What’s the high productivity manufacturing?
High productivity machining can be achieved by using high-feeding rates in machining. This action usually has benefits in that workpieces are machined at a faster rate as compared to when the feed rate is low which consequently means that workout put is higher. Despite this advantage, this process introduces unique issues that should not be ignored. These factors, as an professional CNC machining manufacturer Creatingway will share knowledge to you in this blog.
Below are tips to achieve high productivity manufacturing
Critical Tool Characteristics and Good Tool Holding
The cutting tool used affects the ability to machine the workpiece. Therefore, the shank that needs to be gripped plays a crucial role in the process. It is therefore prudent to know what length of the tool needs to be gripped. On top of this, there are other important factors such as the use of polished shanks, cleaning of the shank and the tool holder which reduce friction. Moreover, it is important to consider the tolerance of roundness and diameter of the cutter shank. These tolerances should be 25 millionths and ISO h6 respectively.
The Importance of Vibration in the Tool
Vibration is a factor that should never be ignored in the analysis of any system. Machine tools that operate at high speeds set up centrifugal forces due to the imbalance of the tool holder which rotates. This is usually caused by the mass distribution which is imperfect around the axis of rotation. From the equation of centrifugal force, we deduce that forces that gyrate the tool out of being concentric are directly proportional to the mass being offset, the square of rotational speed and inversely proportional to the tool holder radius. In this scenario, the solution is to minimize the mass being offset by using tool holders that are intrinsically symmetrical.
Side Lock holders and Slow Speed
Conventional side locks used as end mill are usually inexpensive, easy to set up and use. Despite this, they have disadvantages such as a weak grip power and poor vibration damping. Consequently, this method of holding tools is limited to roughing operations which are carried out at low machining speeds.
Shrink Fit and its relation to better performance of tools
Shrink fit machine tools are suitable for moderate to massive levels of milling . On top of this, they can operate at high speeds and despite this grip, forces rely on the tolerance between the inside diameter of the holder and the tool shank. On the other hand, wall holders that are heavy, offer superior gripping forces. Consequently, breakage of tools is an essential factor that needs to be considered in tooling cost of shrink fits. This is because once these tool shanks break, they cannot be removed from the tool holder.
Collet Chucks and its suitability for high-speed machining
Collet chucks offer strong clamping for high-speed machining and symmetry of the tool. This balance reduces the problem that vibration poses at high machining speeds. On top of this, its set up is fast, easy and no special tools or fixtures are needed. Its runout attributes are usually twice better than those of shrink fit and are about ten times better than those of the tool holders that use sidelocks.
Milling Chucks and their performance to enhance high productivity manufacturing
Milling chucks offer high grip strength and fast tool changing capabilities. To achieve this, they operate based on cam action of needle bearings that consistently apply clamp forces in the collet. The inclination of the tool’s needle in collaboration with multiple rows of needle bearings offer enough gripping force on the tool shank. This clamping power increases in cases where tools with large diameters are used, but runout is reduced as compared to when collet chucks are used. Despite this, their performance is better than when side locks are used.
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