In the fall of 2018, TechSolve had the honor of working with Modern Machine Shop to create a series of videos. Modern Machine Shop’s Editor-in-Chief, Peter Zelinski, worked with our experts to demonstrate and dictate the “what-not-to-dos” in manufacturing. The collaboration resulted in three videos on force analysis, tool coatings and chipbreakers to help uncover some of the misconceptions and confusions within manufacturing processes.
The first video of the series, “What Can Force Analysis Tell You About Your Machining Process?,” details what poorly performing cuts and their cutting force profiles reveal about the machining process. Force analysis can be used to show where the problem area is located within a specific step, as this video details.
Many manufacturers measure cutting forces through the spindle load meter. However, this practice can be inaccurate, leading to failure in the manufacturing process. This first video particularly demonstrates force profiles of gradual tool failure, cutting with an incorrect rake angle, and the development of a built-up edge or worn tool.
At TechSolve, we have the ability to measure forces with greater accuracy through a three-component dynamometer. Using a process with the greatest possible efficiency and effectiveness is necessary so that we can provide the highest quality assistance to manufacturers struggling with monitoring their processes.
Choosing the incorrect tool for a cut, using the incorrect coating, operating with the incorrect chipbreaker or any other number of small decisions can lead to inconsistencies and failure within the machining process. Monitoring with more depth through the three-component dynamometer helps to find the problem, leading to the solution, leading to the greatest possible consistency and reliability.
In the second video, “PVD vs. CVD—How to Choose the Right Tool Coating,” the team works to demonstrate how the correct tool coating could dramatically increase the efficiency and effectiveness of the machining process. Tool coatings are important in the machining process because they provide a level of lubrication and protection against craters in the material, weak and uneven patterns and erosion of the tools.
PVD, or physical vapor deposition, is a line-of-sight coating process which allows for thin coatings and sharp edges. CVD, on the other hand, stands for chemical vapor deposition and is thicker to protect against heat. PVD is typically applied to finishing tools, whereas CVD proves best for roughing. Utilizing the correct tool coating protects the tools and materials for best results of the process.
The final video, “Chipbreakers Are Not All the Same—How to Break Chips Effectively,” dispels the common misconception that all chipbreakers can be utilized in the same way or for the same purposes. Chipbreakers are ornate in their designs yet can typically look similar. Many times if the machine is not breaking the chip it is often not the case that the chip breaker is bad, rather, it is likely that the incorrect chipbreaker is being used for that specific part of the process.
Different chipbreakers are better for different depths of cut and types of feed. Similar to tool coatings, some chipbreakers excel in roughing while others prove best for finishing. Thus, gaining a better understanding of different chipbreakers can increase the effectiveness in the manufacturing process.
In uncovering incorrect practices within manufacturing, this series of videos helps to dispel common misconceptions and confusions in the manufacturing industry. In gaining a deeper understanding of machine monitoring, tool coatings and chipbreakers, manufacturers can be guided to increased effectiveness, accuracy and efficiency to optimize their processes.
Modern Machine Shop and TechSolve’s collaboration aims to guide manufacturers to solutions so that processes may be optimized and quality advanced.