Managing tool cost is like managing your total expenses but nothing can prepare you for the real thing like
Now that I’m done thoroughly mangling that vague metaphor, let’s get down to business. You know you need to save tool cost to improve productivity, but you don’t know how. In this post, I’ll show you effective ways to save extra cost by managing tool's in five simple steps that actually help you in practical terms Ready? Let’s get started.
(Summary)
ways that affect tool life
reason 1 : coolent quality,flow and usage
reason 2 : feedrate and speed balance
reason 3 : run-out of tool
reason 4 : clamping/holding pressure
reason 5 : tool chip washers
reason 6 : excessive material cutting load
Now let's review each step in more detail.
reason 1 : coolent quality,flow and usage
Cooling seems like ignorable issue but it's not.
Most of the times this is the main reason of tool breakage.
Whenever coolent quality (concentration) is low or coolent pressure is low the tool temprature rise due to operation performed and not enough cooling provided at a time when needed thus result in breakage of tool.
reason 2 : feedrate and speed balance
Feed and speed combination is same important as Air fuel mixture in petrol engine.
Setting proper feeds and speeds is the most important thing to consider when starting a milling job. Too much feed rate (cutting speed) will break your cutter. Too slow feed rate, however, will increase the job time significantly. Find the sweet spot. If you see that the cutter is working just fine – rise the speed. If it’s straining too much – lower it.
Remember that feedrate is a complex parameter, which depends on a lot of factors like material hardness, tool geometry (diameter and flutes) and cutting speed.
reason 3 : run-out of tool
This reason will cause the spindle and cutter to vibrate and rise forces of cutting.
A runout on your tool is always present. It is a combination of runout on spindle, collet, and tool itself. It doesn’t mean however that your cutter will always break.
reason 4 : clamping/holding pressure
Proper holding of peice or part is also important if part clamping is not as require then part start to vibrate and while Drilling or reaming etc tool result in breakage
reason 5 : tool chip washers
Clearing tool is a must. But what if you leave those chips during milling? What if they accumulate around your cutter?
Yo have to clean burr sticked on tool otherwise burr will stick in flutes and block entire ways of burr out hence, results in tool breakage
reason 6 : excessive material cutting load
Source : pixabay.com
You must agree "machine didn't take rest until break" so whenever you're giving extra load on your cutters think about your tool capacity. I mean there is a standard way's to define how much material should be remove with respect to speed and feedrate.
If you have to remove large material then use peck drilling or if in case milling then divide in multiple cuts (if you have to remove 3mm then instead of remove in one cut try to divide into 3 it mean 1mm for each cut it will definitely increase little cycle time but offcourse save your tool from excessive heating and reduce Axis load)
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