Every new part brings its own set of challenges to the machinist. Not the least of these is the metal to be cut, milled or drilled. Extremely hard metals like H-13, S-7, M-2, or CPM, and exotic metals like Titanium, Inconel® or Incoloy® can be particularly difficult.
The chief problem manufacturers run into when dealing with these kinds of materials, is failing to look at the whole picture. The tendency is to make do with the equipment on hand, and rely on a new fixture or different cutting tool to solve the problem. As a result you may be able to produce the part, but not efficiently. And as we all know, efficient operation means greater productivity, less scrap and rework and a stronger bottom line.
Looking at the complete picture means thinking about the tooling, fixtures, machine spindle rigidity and speed, and the machine’s control system. In other words, it’s really about the entire package. The tooling is critical, of course, including having the right geometry, hardness, coating and sharpness. On many hard metals, for example, if the tool is too sharp it will wear prematurely. However it’s also important to maintain the proper cutting environment. In some cases, using coolant will shock the tool and cause it to break down quickly. We also know that chips absorb most of the heat produced during machining, so they should be quickly removed from the cutting area.
Obviously the heart of the process is the CNC machine, itself. That’s why it’s important to have equipment with a rigid spindle and tool holder to eliminate the vibrations that cause out-of-tolerance parts. Maintaining constant spindle speed is also vitally important. If the spindle starts to slow down, you’ll burn up the tool. In the same way, the machine’s control must be capable of maintaining consistent acceleration and deceleration, and to quickly process data.
There’s much more to know about machining challenging materials and how to determine if you have the right tooling and machines to handle the job. For expert advice talk your Torrance, CA Haas Factory Outlet consultants. They have the experience to answer your questions, and they can introduce you to the new ST generation of Haas CNC lathes and turning centers. To learn more call (310) 381-0750, email: jphillips@haasfactoryoutlet.com, or visit www.haasfactoryoutlet.com.