Whether it’s a trade publication, a website like this one, or the cutting tool salesperson who stops by every month to show you the latest product offering, there’s no shortage of ideas on how to improve machining processes. And that’s a good thing, because learning about new technology in all its forms is a key to shorter cycle times and increased competitiveness. But did you ever stop to wonder why your cycle times are so long to begin with?
Maybe you experienced poor tool life on a long-running job, and instead of taking the time to troubleshoot the problem, you just turned the feed rate override down a few notches and left it there. Or perhaps you broke too many taps on that batch of Inconel parts last month, and instead of calling the local sales rep for help, you decided to thread them by hand.
Unfortunately, situations like these are all too common, and left unchecked, are a cancer that only metastasizes as a shop begins to accept such competitiveness-killing time-sucks as normal.
Breaking Bad Production Habits
Eric Gardner has seen plenty of them. The North American application specialist at Seco Tools LLC ticked off several pet peeves, starting with overly long tool stickouts. “Shops often try to reduce the number of tools needed for a job or family of parts and end up sticking some cutting tools out farther than they should,” Gardner says. “So instead of using a stubby 1/2-inch diameter end mill for roughing a pocket and an extended-length tool for milling the periphery, they use the longer tool for everything and have to drop their feed rates or depths of cut to compensate for the lack of rigidity.”
For one or two parts, he notes, that’s no big deal. It’s a sure cycle-time killer on larger quantities, however. So are extended-length toolholders, and for the same reasons—poor rigidity and all of the problems such as chatter, deflection, and reduced feed rates that come with them. As such, shops should always opt for the shortest gage-length holders available, even if it means bumping up the tooling budget to do so. Contrary to what many in the machining world have been told over the years, the best way to do this might be moving to a century-old and oft-maligned technology, the Weldon-style side lock toolholder.
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“The bore on a high-quality side lock is ground a few microns off-center, so when it’s tightened, the tool runs perfectly true,” Gardner says. “This eliminates any arguments about runout, and as I suggested earlier, Weldon toolholders offer some of the shortest gage lengths available, bringing the cutter up very close to the spindle face. I've worked on numerous high-production applications where I've intentionally used side lock holders for that very reason.”
How to Stop Babying Tools
Thomas Raun, chief technical officer for Iscar USA, agrees on the last point, although for a different reason. “When we suggest going to traditional Weldon side lock technology, people sometimes look at us like we're crazy because of all they've been told about the higher tool runout,” he says. “But let’s face it, when you're hogging with an end mill, that little bit of runout has very little effect on tool life and is easily offset by the anti-pullout assurance provided by Weldon-style clamping.”
Unless you’re willing to spend the money on a Safe-Lock or comparable anti-pull toolholder, he adds, a side lock is the best way to avoid the end mill creep that will quite possibly scrap an expensive workpiece. It also gives shops the confidence to increase feedrates and depths of cut to their proper levels, thereby eliminating any cycle time lost to babying the cutting tool.
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