MoldMaking Technology

AUG 2018

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moldmakingtechnology.com 21 condition by monitoring them and setting them up properly for each job. But, there is so much more to consider when looking to prolong a cutting tool's utility before having to spend money to replace it. Haimer USA's Drew Strauchen says that moldmakers can benefit by using fine-balanced cutting-tool assemblies that are physically inspected and modified as needed to provide perfect balance characteristics, which in turn have a positive impact on tool life and part finishes. "Unbalance creates centrifugal forces during spindle rotation that creates vibration, which translates to less tool life, poorer finishes, increased spindle wear, more runout and ultimately leads to a reduction in cutting speeds (or metal-removal rates). The faster they go, the more obvious the unbalance problems become," he says. Crystallume's Ed Francis says that moldmakers want longer-lasting and tighter-tolerance cutting tools. "Coatings have advanced with the latest AlTiN coatings for hard milling with the addi- tion of small elements (at less than 1 percent) that promote hardness at high temperatures, like carbon, silicon, boron, oxygen or yttrium," he says, adding that another trend in both PVD and diamond coatings is a move toward a nanocrystal- line coating structure to ensure good uniformity and to maintain tight toler- ances when using carbide cutting tools. He says that the measurement of cutting tools to microns also is quite difficult for most shops, so they need to rely on information that the manufacturer supplies. Measuring the diameter and the end radius of an end mill within a micron is a very difficult task, even for the manufacturer. "Currently, most pro- grams would need to be reprocessed if the tool changes diameter from what was programmed. Crystallume is responding by tightening the tolerance of the cutting tools it sells, adding advanced coatings and supplying individual tools that are accurately measured. Also, some of the new five-axis machines can compensate for tool diameter and radius, making it easier for moldmakers to correct any variations that may occur," he says. National Product Manager-Milling at Iscar (Arlington, Texas), Thomas Raun, says that the introduction of new coatings that are harder and more wear-resistant has resulted in moldmakers gaining up to 50-percent greater tool life, especially in hard-milling applica- tions that generate higher temperatures in the cutting zone. Product offerings for indexable-type cutting tools also continue to advance, he says. "To press an insert with basic geometry is simple. To press an insert with aggressive geometries, which results in more effective shearing of material (especially F O R E X A C T I N G A P P L I C A T I O N S Marposs Diamond systems from Marposs redefine the rules of on-machine part measurement, where precision requirements are pushed to the limits daily. You get consistent quality, high part precision, less waste and more pro fit. Mida ML75P laser tool pre-setting and verification system when your machining applications demand micrometric accuracy. www.marposs.com VOP40p Diamond probes for inspection of extremely complex parts and 3D surfaces, even on the smallest machines. WRP60p Diamond probes for precise part inspection on large, 5-axis milling machines and machining centers. See us in Booths: 135516 - East Building 338719 - South Building

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