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mmsonline.com June 2016 MMS 77 FEATURE "W e call it constant-chip-load machining," Charles Anthony says, referring to one of the CNC programming techniques that ADEX Machining LLC fully embraced after making it a focus of the shop's in-house R&D; program. Mr. Anthony, who is the director of engineering and operations at this 30-person shop in Greenville, South Carolina, has been promoting this concept of "job shop R&D;" for several years, because he believes it gives ADEX a jump on new technology. He has seen this program (unusual for a small machining company) lead to a number of processes or capabilities that might not have been introduced there in time to get ahead of the curve on leading technology trends. He singles out constant-chip-load machining as a prime example of R&D;, because he is sure its benefits would not have been as substantial or pervasive without the R&D; program to give it Discovering a Better (Tool) Path With its in-house R&D; program, this aerospace shop seeks to be a leader, not a follower, on the path to innovation in advanced manufacturing. Finding and embracing a better way to generate tool paths for highly effcient and economical metal removal is a prime example of the value of this program. BY M A R K A LB E RT a boost. In the case of constant-chip-load machin- ing, ADEX had to delve deeply into the performance characteristics of its preferred cutting tools as well as get acquainted with the kinematics of the multi-axis CNC machining centers and vertical turning lathe on its shop floor. What Mr. Anthony calls constant-chip-load machining is one of the most important principles that underlies the Dynamic Motion option for generating tool paths in CNC Software's Master- cam CAD/CAM sof tware. Because ADE X has taken the time and effort to thoroughly master how to apply this option for best ef fect when programming complex parts in titanium and other super alloys, it has provided significant improve- ments in productivity and tool life across a range of workpiece types involving almost every machine tool in the shop. "A better understanding of the cutting tools we use and how our machine tools behave helped us get more out of this approach to generating tool paths," Mr. Anthony says. This knowledge was essential to determining the precise chip-load values that the Dynamic Motion option needs as input to create the rather unusual tool paths that deliver what Mr. Anthony has found to be very productive results. To be clear, Dynamic Motion applies many Only the play of light on the surface of this titanium aerospace part can reveal the telltale tool marks created by the programmed paths of the milling cutter. The apparent patterns reflect the motions that maintain a constant chip load on the cutting tool and follow other rules applied by the CAM software. This part weighed about 70 pounds before machining, but only 17 when completed.