The hallmark of the MA-12500H-W is its ability to provide a good balance of speed and cutting power for machining difficult-to-machine materials, cast iron and aluminum alloys. This makes it well-suited for large-part aerospace machining. The W axis allows for a longer tool stroke to machine complex, difficult-to-reach part features. It has a maximum tool length of 1,100 mm. At IMTS 2016, the MA-12500H-W will be shown with the new W-axis option and in skeleton form. It will Carbide Inserts feature a cutting simulation of a steel construction frame.
Key Features of Okuma’s MA-12500H-W Horizontal Machining Center
Built on an integral bed and base and designed with reinforcing ribs for increased stability and load carrying Carbide Inserts capacity, the MA-12500H incorporates Okuma’s exclusive Thermo-Friendly Concept to achieve maximum thermal stability and accuracy. Standardly-equipped with a 50-taper, 6,000-rpm, 60/50-hp spindle, it is also available with either a 12,000-rpm wide-range spindle or 4,500-rpm heavy-duty spindle.
Visit the company's IMTS showroom for more information.
The Carbide Inserts Website: https://www.estoolcarbide.com/
Much has been made of high efficiency milling in recent years, and for good reason. Roughing cycle times can often be reduced by as much as 80% by using solid end mills, small stepovers, faster feed rates and deeper axial depths of cut. The shortcoming has been that, due to part feature obstructions or CAM system limitations, the cutting technique can often only be used in certain areas of a part so that total part cycle time reduction ends up being much more modest.
CAM developer SolidCAM has an answer for this with its iMachining technology for both 2-axis Z level and full 3D machining. According to Dr. Emil Somekh, the Founder and CEO of SolidCAM, with the ability to intelligently generate high efficiency tool paths for a wider range of cutting conditions, iMachining can reduce total cycle times by as much as 70% and more and deliver dramatically longer tool life in the bargain.
The key to being able to cut faster and improve tool life is to keep a constant force load on the cutter. This reduces the shocks and vibration that occur when material engagement changes abruptly, for example, when a tool hits the corner of a pocket. In high efficiency machining this is most often accomplished by manipulating the tool path to keep tool stepover and feed rate constant, which can result in highly variable chip thickness and force load on the tool. Because the process requires a climb cut, this can also create a lot of air cutting time when repetitive unidirectional passes are required. And it tends to limit use of the technique to certain open features of the part.
Dr. Somekh says iMachining applies a much more flexible approach with the patented ability to dynamically vary the tool VBGT Insert cutting angle (which refers to the degree of radial engagement of the tool with the material) and the feed rate in order to maintain a constant chip thickness and load on the cutting tool. The dynamic feed rate adjustment algorithm supports material cutting angles from 10 to 80 degrees of tool engagement. Constant load and chip thickness is key to the success of iMachining, also with very small cutters and machining in hard or highly abrasive materials.
SolidCAM accomplishes this tool path optimization with two modules:
Combined, these modules apply extremely sophisticated logic to generate the most efficient CNC part programs for any given machine. In fact, machine attributes – max feed rate, spindle speed, HP – and such are used by the wizard to get the best results for a specific machine, tool and Metal Cutting Insert material.
The Spiral Morphing tool path generator is a key enabler to generating the most efficient programs. By maximizing a continuous spiral cutting path, iMachining produces the most efficient cutting strategy because the tool is constantly engaged in the material for greater durations. Part features such as islands or bosses can limit the extent to which the technique can be used. However, the iMachining toolpath algorithm automatically recognizes these features, creates trochoidal tool path around them to incorporate them into a larger pattern, and then continues a spiral path around them to complete a Z-level with the highest percentage of cutter engagement time possible.
iMachining’s patented algorithm is used in iMachining 2D and iMachining 3D. iMachining 2D is made for the roughing and finishing of 2D features, sometimes referred to as prismatic geometry. iMachining 3D is made for the roughing and semi-finish of complex 3D surfaced parts. iMachining 2D uses Machinable Feature Recognition to make geometry setup easy with a single click on a face and iMachining 3D gives the shortest cycle time using its scallop-based roughing.
This constant load cutting strategy is critical for extended tool life. iMachining has been shown to not only give better Material Removal Rates (MRR) than any other toolpath technology, but also amazing increases in tool life… Most people assume that since iMachining is more aggressive with the cutting speeds and feeds, that it should wear out the tool sooner. So how is it that iMachining provides much better tool life?
To understand this, we must first understand solid Carbide Cutters. Carbide is an extremely hard material – it can stand up to compressive forces beyond most other materials and it is also highly resistant to abrasives. These factors make it a great material to use for Cutting Tools, used for cutting Steel, Super Alloys, and most other Metals. Along with being extremely hard, Carbide is also very "Brittle" – it will not stand up to Tensile Force (Bending Force) very well at all.
iMachining ensures that the carbide substrate at the sharp edge of the solid carbide tool flute never sees tensile forces – it only sees compressive forces. Therefore, the sharp edge resists micro chipping, even at elevated performance levels as seen with iMachining, resulting in dramatic improvements to tool life – no other system can manage this balance as well as iMachining.
One other large factor in increasing tool life is the ability to run tools with their full depth of cut. In the past, in order to avoid putting too much stress on brittle tools, other systems would only make shallow cuts to compensate for over engagement. With iMachining, making use of the full cutting depth of the tool, never over stresses it and actually spreads the forces out over a greater area, further maximizing tool life by using the full length of the flute instead of just the bottom 10%.
There is so much more to be said about iMachining, and its amazing successes for customers, we can’t do it justice here. Watch the below interview with SolidCAM’s Ken Merrit, giving an in depth look at iMachining.
Learn more at SolidCAM.com or register for an online demonstration with a SolidCAM expert.
The Carbide Inserts Website: https://www.estoolcarbide.com/product/wckt-aluminum-inserts-p-1224/
The production process for carbide end mills, which are cutting tools used in machining operations, involves several steps. Here's a general overview of the process:
Material Selection: Carbide end mills are typically made from a solid carbide rod. The primary material used is tungsten carbide, which is a combination of tungsten and carbon. Other materials, such as cobalt or nickel, may be added as a binder to enhance the toughness and strength of the end mills. The raw materials are carefully selected based on their quality and desired properties.
Rod Preparation: The selected carbide rods are cut to the required lengths for the end mills. The rods are typically cut using precision cutting tools or machinery.
Grinding the Flutes: The flute grinding process is performed to create the cutting edges of the end mill. Specialized grinding machines are used to grind the flutes into the carbide rod. The number and shape of the flutes may vary depending on the specific design and application of the end mill. This step requires precise control to ensure the desired flute geometry and sharpness.
Grinding the Shank: The shank of the end mill, which is the part that is held by the machine tool, is ground to the appropriate diameter and length. This step ensures that the end mill can be properly held and secured in the machining equipment.
Heat Treatment: After the grinding steps, the carbide end mills undergo heat treatment to enhance their hardness and toughness. This typically involves a process called sintering, where the end mills are XNMU Insert subjected to high temperatures in a controlled atmosphere furnace. The sintering process helps to bond the tungsten carbide particles and further strengthen the end mills.
Grinding the Cutting Edge: After the heat treatment, the cutting edges of the end mill are ground to the required geometry. This step ensures sharp and precise cutting edges that are essential for effective machining.
Inspection and Quality Control: Throughout the production process, quality control measures are implemented to ensure that the carbide end mills meet the required specifications. This involves inspecting the end mills for dimensional accuracy, flute geometry, coating thickness (if applicable), hardness, and other relevant parameters.
It's important to note that the specific Turning Inserts production process may vary depending on the manufacturer, the type of end mill being produced (e.g., square end mill, ball nose end mill, etc.), and the intended applications. Advanced techniques and machinery are often employed to ensure high precision and quality in the production of carbide end mills.
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The Carbide Inserts Website: https://www.cuttinginsert.com/product/apmt-insert/
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Crankshaft is the part of an engine, which translates reciprocating linear piston motion into rotation.
In the engine, It is a necessary to use the counterweights to keep the balance of the reciprocating motion of each piston and connecting rod, as the parts of crankshafts usually. Tungsten heavy alloy is certainly considered as the most appropriate crankshaft material for its properties.
Therefore, tungsten heavy alloy parts can be used as counterweight in machines and vessels as well as aircraft, ships, yachts, space shuttles and anywhere need much heavy but little space, the tungsten heavy alloy crankshaft is widely used in high-performance engines (automobile, racing car, Cermet Inserts motor, fan, diesel, truck, yacht, jet, fan etc.)
