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[Estimated power consumption]
As mentioned earlier, it is very important to determine the power required for a given tool during processing. There have been many publications on how to estimate the power required to process a given material. The following information will cover its basic theory.
A common way to determine the power consumption for a given tool is to multiply the metal removal rate (mrr) by the power factor. The metal removal rate (mrr) is obtained by multiplying the cutting width, cutting depth, and feed amount of the tool used (mrr=aw×ap×f). The power factor (p factor) is a predetermined power constant that varies from material to material. It depends on the amount of power required per minute for a given material for the cutting unit volume (a graph showing the power constants of the material at various hardness values ​​can be found in publications such as the machinist's manual).
It is important to note that this method of expressing power is only an estimate, and many other factors also affect the power calculation. Machine spindle efficiency, material hardness, tool and blade geometry, cutting fluids, tool wear, etc. all affect power demand.
There are many factors to consider when performing power calculations, and the tool is one of many factors, which is obvious. In some cases, when using a high feed tool for roughing applications, the spindle will be the decisive factor in determining the tool diameter used and the machining parameters. For rough machining of any machine tool, especially for smaller spindle-connected machines such as CAT/BT40 and HSK40, in order to avoid undesired spindle loads and cutting conditions while achieving maximum productivity, it is necessary to know how to proceed. The demand power calculation is very important. A machining power calculator has been developed that covers these new high-feed tools and significantly reduces the time and effort required for the estimation of milling, drilling and turning power consumption. By selecting from the pull-down menu and filling in some additional information about the tool name, tool shape, cutting speed, feed, etc., the programmer/operator can quickly determine if the machine is probably having enough power for the application at hand.
[Tool technology for roughing applications]
Since you know how to maximize machine tool productivity when roughing, it's time to discuss how to maximize tool output. Newly designed tools have been developed specifically for maximizing rough metal removal rates, which allow the use of very high feed rates and obtain metal removal rates that can significantly reduce machining cycles and costs during rough machining.
[Kenner Modular High Feed Knife for Rough Machining]
The tool is capable of both 2D and 3D part geometry and it comes in all types and sizes.
Another option for users is the use of modular tools. The flexibility achieved by using different shanks with threaded holes in the head allows the operator to set the overhang length for each application and achieve maximum rigidity.
For smaller applications, tools with replaceable insert designs have been developed for high-feed applications. Available in 10, 12 and 16mm sizes, these tools are capable of very high feed rates (12mm tool steel, feed rate of 7600mm/min at depth of cut 0.6mm), and are effective Improve the metal removal rate of high-speed spindle machines and consume less power. Compared with solid carbide tools, replaceable inserts are also a more economical solution and can successfully mill hardened tool steels with hardness no more than HRC54.
Having a wide range of tools allows employees to effectively match the shapes of the tools and machine tools and parts, and maximize the metal removal rates and productivity for roughing applications in both conventional and high-speed machining centers. In many applications, the use of high-feed roughing tools can achieve near-final shape roughing without sacrificing much, if any, metal removal and productivity through the use of smaller diameter tools.
In fact, compared to other commonly used roughing tools, the metal removal rate of the smaller-diameter, high-feed roughing tool greatly exceeds that of the larger-diameter tool using conventional machining parameters and methods. Another benefit of using a smaller diameter, high feed tool is that the smaller tool can get closer to the final shape of the part and reduce the number of rework and programming required to remove the remaining stock before the finishing begins.
In order to determine if a machine tool has the power to be processed at a given parameter, the personnel involved must be familiar with their machine spindle power diagrams. The spindle power diagram will reveal the power and torque characteristics of the machine, and it is usually divided into two independent ratings (30 minutes and continuous power rating). This map should always be on hand for reference.