Modern Machine Shop

DEC 2016

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BETTER PRODUCTION Shops Using Technology 104 MMS December 2016 mmsonline.com are not needed in the first place." After some experimenting, Mr. Bauer backed of f the feed to achieve a 25-microinch finish, settling at 20 ipm and leaving ever y thing else the same. That change increased cycle time to 39 minutes, which was still 25 percent better than before. Tool life also increased—the shop is now getting the same life out of one tool that it previously got out of eight. These became McGill's standard parameters for the job. Now, r u pt u r e i s a t h i n g of t h e p a s t. I n s te a d, t h e company experiences a failure mode of gradual flank wear, making the process more secure, Mr. Bauer says. "Floor-to-floor time has improved even more because of the reduced tool-servicing downtime," he says. "We get more than an entire shift out of a set of edges and never get a rupture." He e s t i m a t e s t h a t t h e r e t o o l i n g i s s a v i n g McGill about $10,000 a year from all sources. Several key factors contribute to the Di-Pos Hexa's improved per- f o r m a n c e o n D - 2 , despite the material's proclivity to heat hard- ening. "First, the inserts have positive rakes both axially and radially," Mr. Johnson says. "The cut- t i n g a c t i o n i s m o r e cleaving than scraping, w h i c h k n o c k s d o w n c u t t i n g f o r c e s a n d resulting heat." The second factor is an advanced coating that reduces friction and insulates the insert sub- strate from machining h e a t . " T h e c o a t i n g diverts machining heat into the chip as it is flung away from the cutting zone, leaving the tool and workpiece cooler," Mr. Johnson says. "On average, over hundreds o f a p p l i c a t i o n s , t h e coating has improved i n s e r t p e r f o r m a n c e 3 5 p e r c e n t, e v e n o n difficult materials." Other features of the Di-Pos Hexa are thick inserts and large gutters

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