Guest Blog: Douglas Sumner
Product Manager TMS
Remember to replace your spindle cleaners on a regular basis so that you aren't using worn out cleaners. What you think is helping to preserve your valuable Machine Tool/Presetter might actually be hurting it.
When replaced regularly, spindle cleaners can prolong the life of your machine, tools & holders, and tool cleaners enhance the repeatability to the machine spindle. This is a perfect example of how a small investment can make a big impact.
Engineering Manager & Product Manager
Proper clamping techniques will ensure the proper operation of all mechanical milling chucks.
With MEGA Double Power and Hi-Power Slim type chucks it is very important to stop when the nut contacts the main body.
If the operator over tightens or “jerks” the wrench after contact is made, the two faces will wring together making it much more difficult to loosen the tool.
After the tool is released it is also very important to rotate the nut two additional rotations after the tool can be removed. This makes sure the chuck is fully released and is ready to be clamped again.
If the chuck is retightened without fully releasing the nut the gripping strength will be reduced.
The concept of using guide pins to load large fixtures has been around for a long time, and it even applies when incorporating Unilock zero-point clamping systems in your fixturing.
The main Unilock clamping knob is very robust, i.e.: very hard, and as such it can cause damage to a Unilock chuck if a fixture is very heavy or large.
Guide pins are set up on the base, and their corresponding holes or notches located on the edge of the fixture pre-position the fixture so, that as it is being lowered, the knobs do not impact the critical location faces of the clamping chuck.
This also has the added benefit of keeping operators in a safe location not having to use their hands & fingers to fine-adjust a slightly out-of-place fixture being lowered.
Smart Damper products are designed for deep-hole boring with BIG KAISER’s CKB modular boring system, and also for extended reach milling with both inch- and metric-pilot shell mills and face mills.
The original rollout of the Smart Damper for finish boring included an integral BCV50, BBT50 and HSK-A100 tool holder with a CKB modular connection at the business end. A BCV50 integral 1” shell mill holder was also available.
This new design for boring shortens the distance from the damping mechanism to the cutting edge, which is the source of vibration. This produces higher damping effects to the tool assembly to minimize the chatter or vibration – thus achieving better surface finishes and improved metal removal rates.
The EWD Smart Damper damps vibrations and reduces chatter in deep-hole finish boring and extended-reach face milling applications – thus achieving better surface finishes and improved metal removal rates.
For precision machining of deep bores, it has previously been necessary to choose low cutting data in order to prevent vibrations, which massively increases processing time. The EWD Smart Damper overcomes this problem, and enables high cutting parameters to be used. This means that extremely short turnaround times can be achieved, which improves productivity by up to a factor of ten.
To get the maximize life our of your Steep taper rotary toolholders in your CNC milling machines here are some of the best practices you can implement in your shop. Perhaps not all of them can be implemented every day or every time but it's well worth being aware of how to best protect your investment.
Our most widely used finish boring system, KAISER Series 112, features a high precision boring head with a center-mount boring bar or boring bar/insert holder combo with a predefined fixed offset designed to bore one specific size. And although the KAISER system provides a multitude of standard components to create the ideal combination of boring bar and insert holder – you may not always have the ideal combination at your disposal. Don’t fret – that is the beauty of the system. The total boring range of your assembly is reached through radial adjustment of the bar. However, when doing so, there is still always the consideration of balance while assembling the tool. As logic would tell you, the farther away from the boring head’s centerline you offset the boring bar, the greater the unbalance. This affects not only the performance of the tool, but more importantly, the results. And this is especially true for deep hole boring.
To get the greatest productivity and flexibility from the KAISER 112 boring system, we recommend replacing the fixed bar & insert holder with a radial adjustment bar & insert holder which keeps the bar at centerline at all times. This allows for different boring ranges to be reached, all while keeping the tool as balanced as possible.
In this video, Matt Tegelman, Applications Manager and KAISER Product Manager, walks you through the process of adjusting the fixed boring bars and inserts holders. And if balance is a concern, utilizing the radial adjustable option, Matt demonstrates how to properly center the boring bar on both a tool presetter and in a machine spindle, and finally, how to fine-adjust to the desired diameter.
Watch for more of these brief instructional reference videos here on Cut to the Chase blog in the near future.
Tags: balance, boring tool, deep hole boring, How-To, KAISER, Matt Tegelman, tool presetter
We often run end mill "tests" to determine which one performs best. Obviously, our goal is to "win' the test and get more business for our manufacturer's. This is article is about one our "tricks" and it's also why represent both cutting tool manufacturers and rotary tool manufacturers. We want to insure that the products work together.
As a general rule most cutting tool & tolholder manufacturers prefer to use single angle (ER/DR style) collet chucks for general purpose cutting tool applications under 1/2" (12mm). The rules are a bit different in High Speed Machining, as there are many more things to consider, but the problems of TIR at high speeds, where you can hear and feel the chatter, are still there in general end mill cutting operations at lower RPM. It's all about runout and uneven chip load.
End Mill Holders are prone to runout problems for a couple of reasons:
Depending on the application, end mill holders can be used for holding larger insert style end mills, spade drills, etc. But somewhere between 1/2” and 3/4” there is a line that only you can determine when you need to move from a collet chuck to end mill holder. Generally we recommend using end mill holders only for very specific applications
Using small diameter end mills (1/4" and below) in end mill holders with set screws will have a adverse affect of both surface finish and tool life.
Technical Support Blog
At Next Generation Tool we often run into many of the same technical questions from different customers. This section should answer many of your most common questions.
We set up this special blog for the most commonly asked questions and machinist data tables for your easy reference.
If you've got a question that's not answered here, then just send us a quick note via email or reach one of us on our CONTACTS page here on the website
Our technical section is written by several different people. Sometimes, it's from our team here at Next Generation Tooling & at other times it's by one of the innovative manufacturer's we represent in California and Nevada.