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Discover a new and better way.

Discover a new and better way. . 30% Productivity Increase – Guaranteed. Discover a New and Better Way To Program CNC Machines. Discover a new and better way to Program CNC Machines. . www.linkedin.com/scottemillers. www.TheInnovationMachine.com. Scott E. Miller Industrial Engineer.

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Discover a new and better way.

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  1. Discover a new and better way. 30% Productivity Increase – Guaranteed. Discover a New and Better WayTo Program CNC Machines

  2. Discover a new and better way to Program CNC Machines. www.linkedin.com/scottemillers www.TheInnovationMachine.com Scott E. Miller Industrial Engineer

  3. 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

  4. Discover a new and better way to Program CNC Machines. • New Technology • $4M government sponsored R&D Project • $20M in supported research Machining Dynamics • Machining Dynamics • Tool Vibration • Cutting forces • Natural Frequencies • Patented & Proven Technology • 15 US & International Patents • Used by several companies

  5. Discover a new and better way to Program CNC Machines. • Better • Surface Finish • Tighter Tolerances • Faster • Decreased Setup Times • Decreased Cycle Times • Cheaper • Decrease Tooling Cost • Eliminate Chatter and Tool Breakage • Lower Spindle Maintenance Costs

  6. Discover a new and better way to Program CNC Machines. • 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 don’t pay UNTIL and UNLESS you are 100% satisfied • GUARANTEED to increase productivity by 30% • Web Based Project Monitoring Improve CNC Milling Improve CNC Milling

  7. Discover a new and better way to Program CNC Machines. The “Old Way” Setup &Run FirstPart ProgramToolPath Information Resources CNC Programmer CNC Setup Tooling Rep 30 Years Experience What Speed? The Problem: Determining the bestspeed, feed, depth & width of cut

  8. 2 3 4 5 6 7 Discover a new and better way to Program CNC Machines. The “Old Way” Setup &Run FirstPart ProgramToolPath 1 CNC Programmer CNC Setup CHATTER ! The Problem: Determining the bestspeed, feed, depth & width of cut

  9. 3 4 5 6 2 7 Discover a new and better way to Program CNC Machines. The “Old Way” Setup &Run FirstPart ProgramToolPath 1 2 Trial & Error CNC Programmer CNC Setup CHATTER ! The Problem: Determining the bestspeed, feed, depth & width of cut

  10. 4 5 6 2 7 Discover a new and better way to Program CNC Machines. The “Old Way” Setup &Run FirstPart ProgramToolPath 1 2 3 Trial & Error CNC Programmer CNC Setup EXCEEDS MACHINE POWER The Problem: Determining the bestspeed, feed, depth & width of cut

  11. 3 5 6 2 7 4 Discover a new and better way to Program CNC Machines. 4 The “Old Way” Setup &Run FirstPart ProgramToolPath 1 2 3 4 Trial & Error CNC Programmer CNC Setup CHATTER ! The Problem: Determining the bestspeed, feed, depth & width of cut

  12. 3 6 2 7 4 Discover a new and better way to Program CNC Machines. 5 4 The “Old Way” Setup &Run FirstPart ProgramToolPath 1 2 3 4 5 Trial & Error CNC Programmer CNC Setup CHATTER ! The Problem: Determining the bestspeed, feed, depth & width of cut

  13. 3 2 7 4 Discover a new and better way to Program CNC Machines. 5 4 The “Old Way” Setup &Run FirstPart ProgramToolPath 6 6 1 2 3 4 5 Trial & Error CNC Programmer CNC Setup CHATTER ! The Problem: Determining the bestspeed, feed, depth & width of cut

  14. 3 2 4 Discover a new and better way to Program CNC Machines. 5 4 The “Old Way” Setup &Run FirstPart ProgramToolPath 6 6 1 2 3 4 5 7 7 Trial & Error CNC Programmer CNC Setup STABLE PREFERRED SPEED The Problem: Determining the bestspeed, feed, depth & width of cut

  15. 3 2 4 Discover a new and better way to Program CNC Machines. 5 4 The “Old Way” Setup &Run FirstPart ProgramToolPath 6 6 1 2 3 4 5 7 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 The Problem: Determining the bestspeed, feed, depth & width of cut

  16. 3 2 4 Discover a new and better way to Program CNC Machines. 5 4 The “Old Way” Setup &Run FirstPart ProgramToolPath 6 6 1 2 3 4 5 7 7 How much does this cost? The Problem: Determining the bestspeed, feed, depth & width of cut

  17. 3 2 4 Discover a new and better way to Program CNC Machines. 5 4 The “Old Way” Setup &Run FirstPart ProgramToolPath 6 Is this really the best? 7 7 Can these beimproved ? The Problem: Determining the bestspeed, feed, depth & width of cut

  18. Discover a new and better way to Program CNC Machines. The Problem: Determining the bestspeed, feed, depth & width of cut Setup &Run FirstPart ProgramToolPath Machining Dynamics CNC Setup CNC Programmer Root Cause of Problem Doesn’t have Machining Dynamics Information

  19. Discover a new and better way to Program CNC Machines. What is Machining Dynamics? 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 forceswhen the tool impacts the workpiece.

  20. Discover a new and better way to Program CNC Machines. What is Machining Dynamics? Machining Dynamics Tool Path Frequency & Tool Point Frequency

  21. 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) Tooth Path Frequency (Hz) = 60 Seconds Spindle Speed Number of Teeth

  22. Discover a new and better way to Program CNC Machines. Tool Path Frequency 1 sec (75 RPM x 4 teeth) / 60 = 5 Hz

  23. Discover a new and better way to Program CNC Machines. Tool Path Frequency 1 sec (75 RPM x 4 teeth) / 60 = 5 Hz 5 impacts

  24. Discover a new and better way to Program CNC Machines. Tool Path Frequency 1 sec (135 RPM x 4 teeth) / 60 = 9 Hz

  25. Discover a new and better way to Program CNC Machines. Tool Path Frequency 1 sec 9 impacts (135 RPM x 4 teeth) / 60 = 9 Hz

  26. Discover a new and better way to Program CNC Machines. Tool Path Frequency 1 sec (255 RPM x 4 teeth) / 60 = 17 Hz

  27. Discover a new and better way to Program CNC Machines. Tool Path Frequency 1 sec 17 impacts (255 RPM x 4 teeth) / 60 = 17 Hz

  28. Discover a new and better way to Program CNC Machines. Tool Path Frequency 1 sec 1 sec 1 sec (75 RPM x 4 teeth) / 60 = 5 Hz 5 impacts 9 impacts (135 RPM x 4 teeth) / 60 = 9 Hz 17 impacts (25 RPM x 4 teeth) / 60 = 17 Hz

  29. Discover a new and better way to Program CNC Machines. Tool Path Frequency .01 sec .01 sec .01 sec (7500 RPM x 4 teeth) / 60 = 500 Hz (13500 RPM x 4 teeth) / 60 = 900 Hz (25500 RPM x 4 teeth) / 60 = 1700 Hz

  30. Discover a new and better way to Program CNC Machines. Tool Point Frequency Dynamic tool movement in response to cutting forces

  31. 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 Projection Tool Holder # of Teeth Helix Angle Drawbar Force Runout Tool Holder Length Reduced Shank Damped Toolholders Imbalance Simultaneous Fit

  32. Discover a new and better way to Program CNC Machines. Tool Point Frequency The impact causes the tool to vibrate The tool will vibrate at its natural frequency (Time to deflect and return to centerline) = Tool Point Frequency (Hz) 1 sec

  33. 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.

  34. Discover a new and better way to Program CNC Machines. Tool Point & Path Frequencies Problems ProgrammedDepth ToShallow ToDeep

  35. Discover a new and better way to Program CNC Machines. Tool Point & Path Frequencies Problems Bad Timing Bad Timing • Chatter • Poor Tool Life • Poor Surface Finish • Scrap • High Power • Hard on Spindle Too Deep Too Shallow Excessive Chipload Good Timing Bad Timing • Stable Cut • Increased Tool Life • Better Surface Finish • Energy Efficiency • Higher Speeds & Feeds Programmed Depth

  36. 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 increaseor decrease the speed? Lower the Spindle Speed

  37. 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) • 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 Depth of Cut Increase in depth = Increase in tool deflection

  38. Discover a new and better way to Program CNC Machines. Chatter Zones (unsynched) Machining Dynamics Stable Zones (Tool Path and Point Frequencies are Synched)

  39. Where most cutters run Discover a new and better way to Program CNC Machines. Machining Dynamics Conventional Region You are Here Low Performing Region HSM Region

  40. Discover a new and better way to Program CNC Machines. Machining Dynamics Conventional Region You should be Here400+% higher MRR You are Here Low Performing Region HSM Region

  41. Discover a new and better way to Program CNC Machines. Machining Dynamics Conventional Region The UNKNOWN Region Low Performing Region HSM Region

  42. Discover a new and better way to Program CNC Machines. The Solution: Machining Dynamics Information (Stable Speeds) Setup &Run FirstPart ProgramToolPath Machining Dynamics 30 Years Experience CNC Setup CNC Programmer Information Resources 99.9% of manufacturershave no way of knowing the Stable SPEEDS of each “Cutting System”. For a programmer with limited machiningexperience, the first ‘educated guess’ could be from a handbook or the internet. Tooling Rep STABLE PREFERRED SPEED Know theStable Speeds(Green = Stable)(Yellow = Unstable)

  43. 7 Discover a new and better way to Program CNC Machines. The Solution: Machining Dynamics Information (Stable Speeds) Setup &Run FirstPart ProgramToolPath Machining Dynamics 30 Years Experience Trial & Error CNC Setup CNC Programmer Information Resources 99.9% of manufacturershave no way of knowing the Stable SPEEDS of each “Cutting System”. 1 2 3 4 5 6 For a programmer with limited machiningexperience, the first ‘educated guess’ could be from a handbook or the internet. Tooling Rep STABLE PREFERRED SPEED Know theStable Speeds(Green = Stable)(Yellow = Unstable)

  44. Discover a new and better way to Program CNC Machines. The Solution: Machining Dynamics Information (Stable Speeds) Setup &Run FirstPart ProgramToolPath Machining Dynamics THE BESTParameters! 30 Years Experience CNC Setup CNC Programmer Information Resources 99.9% of manufacturershave no way of knowing the Stable SPEEDS of each “Cutting System”. For a programmer with limited machiningexperience, the first ‘educated guess’ could be from a handbook or the internet. Tooling Rep STABLE PREFERRED SPEED Know theStable Speeds(Green = Stable)(Yellow = Unstable)

  45. Discover a new and better way to Program CNC Machines. The Solution: Machining Dynamics Information (Stable Speeds) Setup &Run FirstPart ProgramToolPath Machining Dynamics CNC Setup CNC Programmer Information Resources 99.9% of manufacturershave no way of knowing the Stable SPEEDS of each “Cutting System”. For a programmer with limited machiningexperience, the first ‘educated guess’ could be from a handbook or the internet. STABLE PREFERRED SPEED Know theStable Speeds(Green = Stable)(Yellow = Unstable)

  46. Discover a new and better way to Program CNC Machines.

  47. Discover a new and better way to Program CNC Machines.

  48. Discover a new and better way to Program CNC Machines.

  49. Discover a new and better way to Program CNC Machines.

  50. Discover a new and better way to Program CNC Machines.

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