Discover a new and better way. Discover a New and Better Way To Program CNC Machines 30%...
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- Slide 1
- Slide 2
- Discover a new and better way. Discover a New and Better Way To
Program CNC Machines 30% Productivity Increase Guaranteed.
- Slide 3
- Discover a new and better way to Program CNC Machines.
www.linkedin.com/scottemillers www.TheInnovationMachine.com Scott
E. Miller Industrial Engineer
- Slide 4
- Discover a new and better way to Program CNC Machines. In 5
Minutes What is New? Why is it Better? How is it implemented? The
Old Way & Problems The New Way & Solutions Success Stories
Next Steps
- Slide 5
- Discover a new and better way to Program CNC Machines. New
Technology $4M government sponsored R&D Project $20M in
supported research Machining Dynamics Tool Vibration Cutting forces
Natural Frequencies Patented & Proven Technology 15 US &
International Patents Used by several companies
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- Discover a new and better way to Program CNC Machines. Faster
Decreased Setup Times Decreased Cycle Times Cheaper Decrease
Tooling Cost Eliminate Chatter and Tool Breakage Lower Spindle
Maintenance Costs Better Surface Finish Tighter Tolerances
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- Discover a new and better way to Program CNC Machines. Improve
CNC Milling Simple Implementation Less than 15 minutes of internal
resources per tool Works with your existing machines, tools, and
software Affordable (only $250 per tool), quick payback, high ROI
You dont pay UNTIL and UNLESS you are 100% satisfied GUARANTEED to
increase productivity by 30% Web Based Project Monitoring
- Slide 8
- Discover a new and better way to Program CNC Machines. CNC
Programmer The Problem: Determining the best speed, feed, depth
& width of cut What Speed? The Old Way CNC Setup Program Tool
Path Setup & Run First Part Tooling Rep Information Resources
30 Years Experience
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- Discover a new and better way to Program CNC Machines. CNC
Programmer The Problem: Determining the best speed, feed, depth
& width of cut The Old Way CNC Setup Program Tool Path Setup
& Run First Part CHATTER ! 723456 1
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- Discover a new and better way to Program CNC Machines. CNC
Programmer The Problem: Determining the best speed, feed, depth
& width of cut The Old Way CNC Setup Program Tool Path Setup
& Run First Part CHATTER ! 7 2 3456 12 Trial & Error
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- Discover a new and better way to Program CNC Machines. CNC
Programmer The Problem: Determining the best speed, feed, depth
& width of cut The Old Way CNC Setup Program Tool Path Setup
& Run First Part EXCEEDS MACHINE POWER 7 2 456 123 Trial &
Error
- Slide 12
- Discover a new and better way to Program CNC Machines. CNC
Programmer The Problem: Determining the best speed, feed, depth
& width of cut The Old Way CNC Setup Program Tool Path Setup
& Run First Part CHATTER ! 7 2 3 4 56 4 1234 Trial &
Error
- Slide 13
- Discover a new and better way to Program CNC Machines. CNC
Programmer The Problem: Determining the best speed, feed, depth
& width of cut The Old Way CNC Setup Program Tool Path Setup
& Run First Part CHATTER ! 7 2 3 45 6 4 12345 Trial &
Error
- Slide 14
- Discover a new and better way to Program CNC Machines. CNC
Programmer The Problem: Determining the best speed, feed, depth
& width of cut The Old Way CNC Setup Program Tool Path Setup
& Run First Part CHATTER ! 7 2 3 45 6 4 12345 6 Trial &
Error
- Slide 15
- Discover a new and better way to Program CNC Machines. CNC
Programmer The Problem: Determining the best speed, feed, depth
& width of cut The Old Way CNC Setup Program Tool Path Setup
& Run First Part 7 2 3 45 6 4 STABLE PREFERRED SPEED 12345 6 7
Trial & Error
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- Discover a new and better way to Program CNC Machines. The
Problem: Determining the best speed, feed, depth & width of cut
The Old Way Program Tool Path Setup & Run First Part 7 2 3 45 6
4 12345 6 7 Trial & Error Resulting Problems Excessive Setup
Time Lack of Skilled Resources (Programmers & Setup) Poor tool
life, chatter, tool breakage Poor surface finish or loss tolerances
Long cycle times due to suboptimal machine parameter
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- Discover a new and better way to Program CNC Machines. The
Problem: Determining the best speed, feed, depth & width of cut
The Old Way Program Tool Path Setup & Run First Part 7 2 3 45 6
4 12345 6 7 Setup Costs Per Trial TimeHours$/HrCost CNC
Programmer1$45 Setup / Machine1$75 MaterialQtyUnit CostCost Tools
Broken0$98$0 Parts Scrapped1$5 TOTAL$125 Total Setup Cost Cost Per
Trial$125 Number of Trials7 Total Cost$875 How much does this
cost?
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- Discover a new and better way to Program CNC Machines. The
Problem: Determining the best speed, feed, depth & width of cut
The Old Way Program Tool Path Setup & Run First Part 7 2 3 45 6
4 7 Is this really the best? Can these be improved ?
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- Discover a new and better way to Program CNC Machines. Setup
& Run First Part CNC Setup CNC Programmer Program Tool Path The
Problem: Determining the best speed, feed, depth & width of cut
Root Cause of Problem Doesnt have Machining Dynamics Information
Machining Dynamics
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- Discover a new and better way to Program CNC Machines.
Machining Dynamics What is Machining Dynamics? The branch of
physics concerned with the forces that change or produce motion of
bodies For CNC Machining the study of the resulting forces when the
tool impacts the workpiece.
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- Discover a new and better way to Program CNC Machines.
Machining Dynamics What is Machining Dynamics? Tool Path Frequency
Tool Point Frequency &
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- Discover a new and better way to Program CNC Machines. Tool
Path Frequency The number of tooth impacts in 1 second (Spindle
Speed) x (Number of Teeth) 60 Seconds Tooth Path Frequency (Hz) =
Number of Teeth Spindle Speed
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- Discover a new and better way to Program CNC Machines. 1 sec
Tool Path Frequency (75 RPM x 4 teeth) / 60 = 5 Hz
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- Discover a new and better way to Program CNC Machines. 1 sec
Tool Path Frequency (75 RPM x 4 teeth) / 60 = 5 Hz 5 impacts
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- Discover a new and better way to Program CNC Machines. 1 sec
Tool Path Frequency (135 RPM x 4 teeth) / 60 = 9 Hz
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- Discover a new and better way to Program CNC Machines. 1 sec
Tool Path Frequency (135 RPM x 4 teeth) / 60 = 9 Hz 9 impacts
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- Discover a new and better way to Program CNC Machines. 1 sec
Tool Path Frequency (255 RPM x 4 teeth) / 60 = 17 Hz
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- Discover a new and better way to Program CNC Machines. 1 sec
Tool Path Frequency (255 RPM x 4 teeth) / 60 = 17 Hz 17
impacts
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- Discover a new and better way to Program CNC Machines. 1 sec
Tool Path Frequency (75 RPM x 4 teeth) / 60 = 5 Hz (135 RPM x 4
teeth) / 60 = 9 Hz (25 RPM x 4 teeth) / 60 = 17 Hz 5 impacts 9
impacts 17 impacts
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- Discover a new and better way to Program CNC Machines..01 sec
Tool Path Frequency (7500 RPM x 4 teeth) / 60 = 500 Hz (13500 RPM x
4 teeth) / 60 = 900 Hz (25500 RPM x 4 teeth) / 60 = 1700 Hz
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- Discover a new and better way to Program CNC Machines. Tool
Point Frequency Dynamic tool movement in response to cutting
forces
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- Discover a new and better way to Program CNC Machines. Tool
Point Frequency Dynamic tool movement in response to cutting forces
Depth & Width of Cut Tool Holder # of Teeth Tool Projection
Helix Angle Runout Tool Holder Length Drawbar Force Reduced Shank
Imbalance Simultaneous Fit Damped Toolholders
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- Discover a new and better way to Program CNC Machines. Tool
Point Frequency The impact causes the tool to vibrate (Time to
deflect and return to centerline) 1 sec Tool Point Frequency (Hz) =
The tool will vibrate at its natural frequency
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- Discover a new and better way to Program CNC Machines. Tool
Point Frequency At impact, the tool deflects and returns to its
centerpoint. The tool does not fully dissipate because the next
tooth results in another vibration.
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- Discover a new and better way to Program CNC Machines. Tool
Point & Path Frequencies Problems Programmed Depth To Shallow
To Deep
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- Discover a new and better way to Program CNC Machines. Tool
Point & Path Frequencies Problems Too Deep Too Shallow Chatter
Poor Tool Life Poor Surface Finish Scrap High Power Hard on Spindle
Bad Timing Programmed Depth Bad Timing Stable Cut Increased Tool
Life Better Surface Finish Energy Efficiency Higher Speeds &
Feeds Bad Timing Good Timing Excessive Chipload
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- Discover a new and better way to Program CNC Machines. Syncing
the Tool Point & Path Frequencies Change the Tool Path
Frequency (adjust rotation of the tool) Easy Change Common in many
shops Trained ear to recognize a bad sound How do you know whether
to increase or decrease the speed? Lower the Spindle Speed
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- Discover a new and better way to Program CNC Machines. Sync the
Tool Point & Path Frequencies Change the Tool Point Frequency
(adjust deflection of the tool) Increase Depth of Cut Dangerous!
Can easily break a tool No way of knowing the effect of changes
What people chase every day Searching for a unknown, moving target
Increase in depth = Increase in tool deflection
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- Discover a new and better way to Program CNC Machines.
Machining Dynamics Chatter Zones (unsynched) Stable Zones (Tool
Path and Point Frequencies are Synched)
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- Discover a new and better way to Program CNC Machines. HSM
Region Machining Dynamics Conventional Region Low Performing Region
Where most cutters run Where most cutters run You are Here
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- Discover a new and better way to Program CNC Machines. HSM
Region You should be Here 400+% higher MRR Machining Dynamics
Conventional Region Low Performing Region You are Here
- Slide 42
- Discover a new and better way to Program CNC Machines. HSM
Region Machining Dynamics Conventional Region Low Performing Region
The UNKNOWN Region
- Slide 43
- Discover a new and better way to Program CNC Machines. Setup
& Run First Part CNC Setup CNC Programmer Program Tool Path The
Solution: Machining Dynamics Information (Stable Speeds) 99.9% of
manufacturers have no way of knowing the Stable SPEEDS of each
Cutting System. For a programmer with limited machining experience,
the first educated guess could be from a handbook or the internet.
30 Years Experience Tooling Rep Information Resources Know the
Stable Speeds (Green = Stable) (Yellow = Unstable) STABLE PREFERRED
SPEED Machining Dynamics
- Slide 44
- Discover a new and better way to Program CNC Machines. Setup
& Run First Part CNC Setup CNC Programmer Program Tool Path The
Solution: Machining Dynamics Information (Stable Speeds) 99.9% of
manufacturers have no way of knowing the Stable SPEEDS of each
Cutting System. For a programmer with limited machining experience,
the first educated guess could be from a handbook or the internet.
30 Years Experience Tooling Rep 7123456 Trial & Error Know the
Stable Speeds (Green = Stable) (Yellow = Unstable) Information
Resources Machining Dynamics STABLE PREFERRED SPEED
- Slide 45
- Discover a new and better way to Program CNC Machines. Setup
& Run First Part CNC Setup CNC Programmer Program Tool Path The
Solution: Machining Dynamics Information (Stable Speeds) 99.9% of
manufacturers have no way of knowing the Stable SPEEDS of each
Cutting System. For a programmer with limited machining experience,
the first educated guess could be from a handbook or the internet.
30 Years Experience Tooling Rep Know the Stable Speeds (Green =
Stable) (Yellow = Unstable) Information Resources Machining
Dynamics STABLE PREFERRED SPEED THE BEST Parameters!
- Slide 46
- Discover a new and better way to Program CNC Machines. Setup
& Run First Part CNC Setup CNC Programmer Program Tool Path The
Solution: Machining Dynamics Information (Stable Speeds) 99.9% of
manufacturers have no way of knowing the Stable SPEEDS of each
Cutting System. For a programmer with limited machining experience,
the first educated guess could be from a handbook or the internet.
Know the Stable Speeds (Green = Stable) (Yellow = Unstable)
Information Resources STABLE PREFERRED SPEED Machining
Dynamics
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- Discover a new and better way to Program CNC Machines.
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- Setup & Run First Part CNC Setup CNC Programmer Program
Tool Path The Solution: Machining Dynamics Information (Stable
Speeds) 99.9% of manufacturers have no way of knowing the Stable
SPEEDS of each Cutting System. For a programmer with limited
machining experience, the first educated guess could be from a
handbook or the internet. Know the Stable Speeds (Green = Stable)
(Yellow = Unstable) STABLE PREFERRED SPEED Solution Results
Decrease in setup time Skilled resources focus on other variables
(coolant, programming strategies, etc.) Increase tool life,
eliminate chatter & tool breakage Better surface finish &
tighter tolerances Decrease in cycle time
- Slide 60
- Discover a new and better way to Program CNC Machines. Setup
& Run First Part CNC Setup CNC Programmer Program Tool Path The
Solution: Machining Dynamics Information (Stable Speeds) 99.9% of
manufacturers have no way of knowing the Stable SPEEDS of each
Cutting System. For a programmer with limited machining experience,
the first educated guess could be from a handbook or the internet.
Know the Stable Speeds (Green = Stable) (Yellow = Unstable)
Information Resources STABLE PREFERRED SPEED Machining
Dynamics
- Slide 61
- Tooling Rep Information Resources 30 Years Experience Discover
a new and better way to Program CNC Machines. Setup & Run First
Part CNC Setup CNC Programmer Program Tool Path OLD WAY vs. NEW WAY
99.9% of manufacturers have no way of knowing the Stable SPEEDS of
each Cutting System. For a programmer with limited machining
experience, the first educated guess could be from a handbook or
the internet. Know the Stable Speeds (Green = Stable) (Yellow =
Unstable) STABLE PREFERRED SPEED Machining Dynamics
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- Discover a new and better way to Program CNC Machines.
Implementation - Simple, Fast, 3 Step Process 3. You Utilize 1. We
Collect 2. We Analyze 10 min/tool 5 50 min/tool Setup & Run
Part Program Tool Path Improve CNC Milling
- Slide 63
- Discover a new and better way to Program CNC Machines. Decrease
Cycle Time Know crucial STABLE SPEED information Eliminate Trial
& Error End Result is optimal instead of acceptable 4.5x
Improvement after 5 min tap test Decrease Setup Time We guarantee a
30% average decrease Aerospace Manufacturer - 45% Military Depot -
85% Job Shop 30 sec/part on 30,000 parts Increase Tool Life Small
job shop saves $10k of Stainless Steel Eliminate chatter marks
Decrease Scrap Die Shop stops chatter, saves $8750/yr Compare tools
to determine best option Improve Spindle Life Improve CNC
programming labor utilization Improve CNC setup labor utilization
Reallocate experienced labor Supplement Scarce Labor Resources Big
3 Automaker 4x longer spindle Life The Benefits / Success
Stories
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- Discover a new and better way to Program CNC Machines. Cost
Savings & ROI
- Slide 65
- Discover a new and better way to Program CNC Machines. Cost
Savings & ROI We guarantee a 30% Productivity Increase These
figures TRIPLE !
- Slide 66
- Discover a new and better way to Program CNC Machines. Learn
More & Contact Us for Testing www.MachiningDynamics.com Website
Videos Literature Media Articles Cost Savings / ROI Calculations
Success Stories Call or Visit Us The Innovation Machine 30 S.
Wacker Drive Suite 2200 Chicago, IL 60606 312-238-9362
- Slide 67
- Discover a new and better way to Program CNC Machines. Learn
More & Contact Us for Testing www.MachiningDynamics.com Website
Next Steps TEST MY FIRST TEN CALL ME WEBCAST SIGNUP Call or Visit
Us The Innovation Machine 30 S. Wacker Drive Suite 2200 Chicago, IL
60606 312-238-9362
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- Discover a new and better way to Program CNC Machines. Summary
Simple 3 Step Implementation Collect, Analyze, Utilize GUARANTEED
to increase productivity by 30% Less than 15 minutes of internal
resources per tool Works with your existing machines, tools, and
software Affordable (only $250 per tool), quick payback, high ROI
You dont pay UNTIL and UNLESS you are 100% satisfied
- Slide 69
- Discover a new and better way to Program CNC Machines. Learn
More www.MachiningDynamics.com Website Videos Literature Media
Articles Cost Savings / ROI Calculations Success Stories Call or
Visit Us The Innovation Machine 30 S. Wacker Drive Suite 2200
Chicago, IL 60606 312-238-9362