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Eric Sun from OrangeVise releases another cool video.

October 14, 2013, 1:21 am by Eldar Gerfanov

This is another video from his Productivity Series.

In there we get a quick demonstration of HSM techniques Eric is using to produce his beatiful vise.

Also my own HSMAdvisor is featured there!

Thank you Eric!

Orange Vise are produced in the USA.

Check out this website for more info http://orangevise.com


Ways in which High Speed Machining (HSM ) works

October 12, 2013, 12:32 pm by Eldar Gerfanov

Lately there have been a lot of really interesting HSM topics on PracticalMachinist forums.

In one of them a guy who owns his own resharpening business posted a video of his endmill milling a block of D2 hardened to over 60 RC.
The forum topic is located here First try on D2 62Rc(video)

Here is his post so you know what we are talking about:

Quote:
In an effort to perfect our speeds and feeds while hardmilling, this is the first try. Its not right yet, but far from a failure. I apologize for the language at the end, but I do not edit my videos. The endmill was a reground garr VRX at .353 diameter. Parameters were 750 sfm, .018 radial, .300 axial and .004 ipt.
The next run will be at 650 sfm, .006 ipt using a mist sprayer. Also, any small areas will be blocked off to be ran at lower speeds to allow cooling time for the cutter. Just a note for anyone using a Mag Fadal, The E-stop button is not quick enough, use feed hold. The endmill was badly worn on the corners, but not broken, and will be resharpened and used again.

In the ensuing discussion i posted my own take on how and why HSM works

Quote:
HSM works in many ways.

1) Reduced cutting time per edge per revolution allows it to cool down more.
2) Chip thinning allows to increase chipload (advancement per tooth per revolution)
3) Increased depth of cut combined with shallow radial positively affects deflection. Tool bends less as it is more rigid towards the tool holder.
4) Higher cutting speed actually reduces cutting forces as heat generated in the cutting zone makes it easier to shear off a layer of metal. Yet because the time of contact is so small, most of the heat is carried away with the chip.
5) Higher RPM also allows to get rid of hot chips faster thus further reducing heat transferred to the tool.
6) Higher feedrate actually reduces relative cutting speed.
7) At high axial engagements more than one flute is in contact with the workpiece at different points along the axis of the tool. This too helps combat vibrations and chatter.
8) You are using more of the tool than just its tip, so technically you can do more work with one tool before it gets dull.
9) lastly it looks cool as hell and is very impressive. Whenever we know visitors or bosses are coming we try to make sure some HSM is going on even if application does not merit that
I am not sure if the air that is moved by the endmill is doing much, but i suspect he didn't mean exactly that.

 


New FSWizard for android is out!

October 8, 2013, 11:40 pm by Eldar Gerfanov

I have added Fillet Calculator to our android version.

It allsows to calculate tangent points on a circle and two lines.

All you need to specify is an angle beteen them and a radius.

Also lines intersection point can be moved around.

As a result it returns coordinates of the points and the centre of the circle.


2013-10-08_21-57-55.png 2013-10-08_21-57-55.png

FSWizard:Android update is coming soon!

October 5, 2013, 10:21 am by Eldar Gerfanov

Normally i can't keep secrets and announce what i am working on.

But this time is different.

I can only tell you that i am working on a unique feature in our android version

Nobody has done anything like that. I can only tell you that i will be adding more tools for aiding manual programming on the control.

Check back soon. Like my facebook page to get the latest updates on our many projects.

The link is on the right :)

 


Huge machine milling miniscule detail on a car scale model

September 29, 2013, 10:05 am by Eldar Gerfanov

Check this video out.

The whole thing is pretty impressive, but the best part starts closer to the middle of the video. At around 3:20 you can see the size of the machine. Truly amazing.

Note: TURN YOUR VOLUME DOWN


Working with HSMAdvisor myCutDB Tool Library

September 25, 2013, 10:09 pm by Eldar Gerfanov

I have been asked to create a tutorial on how to work with the tool library, so here it is.

myCut Tool Database is quite a unique thing.

It not only contains all of your tools, but also each and every tool can have multiple operations or "Cuts" attached to it.

Everything is very simple.

Database contains Libraries

Libraries contain Tools

And Tools contain Cuts


Each entity behaves according to specific rules and "knows" specific kind of data.

Please read more to learn how it all works....
...Read More


HSMAdvisor v0.601 Release

September 24, 2013, 12:07 am by Eldar Gerfanov

I have just uploaded a new release of HSMAdvisor.

I have decided to extend trials every time major releases come out.

This will happen every several months or so.

This release is pretty big. So every one who has not purchased yet gets 30 days more to play with it.

We have material cross-reference tool.

It allows you to quickly figure out material group for a large number of materials. Around 1000 of them.
You can access it by pressing "MORE" button next to material drop-down list.

Here is it looks:

Second Big thing is new tool life estimator.

It allows to show you how tool life reacts to changes in speed, feed rate and depth of cut.

It is a percentage based on normal shoulder milling cut that should equal 100%

Nobody else has this feature- it is absolutely unique to HSMAdvisor and that is in part why i decided to extend trials this time.

Besides tool life gage there is a new tab in results area.

It is called Gages.

It shows important information like what percentage of deflection, torque and machine load we are running at the moment.

It helps to figure out at a glance if something is out of whack.

As always feedback is welcome.


New Single Seat License is now available!!

September 19, 2013, 12:51 am by Eldar Gerfanov

I was originally going to introduce new License types on september the 1st.

But it turned out to be a little harder than i thought and everything got delayed by almost one month.

 

The revised date of september the 30th is still standing though.

So until then 3 seat license will still be available for 75$ and a new single seat will be available for just 49$ !!!

If you have been procrastinating, this is your time to save.

Also check out my Online store that i coded myself.

http://www.hsmadvisor.com/index.php?page=buy


Niagara Elite HP 3 flute Hi Performance Endmill Test

September 18, 2013, 12:22 pm by Eldar Gerfanov

Here is a video of a 3 flute Hi-performance endmill slotting aluminum 0.75" deep per pass.

Well, not entirely slottimg, more like pocketing, but the very first move is a full width slot.

Stepover is 0.4"

First i calculated the cut on HSMAdvisor.

Used 6061 aluminum as material and HP endmill at a tool type.

Tool torque and deflection limits were both set at 100% and performance slider was at maximum.

This is what it came up with:

S9127 RPM 125 IPM.

Full slot, 0.75" deep.

45 in^3/min mrr.

Looking at how easy it went i think i should allow for more load in my calculator.

If you have not yet tried HSMAdvisor, make sure you do.

You will be amazed at how much productivity you have been missing out on.


If you are working in mold-making, prototyping or even in a job shop you have had to use unusual form tooling before in your life.

Form tooling is often used to machine undercuts and other features on regular 3 axis machines that would otherwise require a multi axis machining centre or are not machinable o at all.

The classical example of a form tool is a tear-drop ball mil, also known as a "lollipop". It has a tip with a certain diameter and a much smaller shank that produces enough clearance to machine undercuts on straight walls. It can also be used to regular surface finishing and 2d milling.

Another example is a T-slot cutter that is used to produce key-ways and t- slots

The main thing to consider when machining with reduced shank end mils is deflection and torque.

While deflection is especially dangerous for long tools, torque becomes much more important for tools with severely reduced shank.

Torque required to break a tool is directly proportional to the diameter of its shank.

And when shank diameter is much smaller than the tip diameter it does not matter how short that weak portion is: unless you compensate for it you will snap the tool.

The first thing that crosses the mind in many such cases is "I gotta run this tool very slow". It may take forever, but in many cases job gets somewhat done.

Contrary to that many experienced machinists have been proponents of different approach. Instead of reducing feed rate to the point of rubbing and below, it is much more productive to reduce cutter engagement if possible and leave feed rate settings largely unchanged.

Trying to keep proper chip load is even more important when machining work-hardenable materials like stainless steel and titanium. In those cases rubbing is not just unproductive, it leads to a very premature, in many cases instantaneous tool failure.

Just how much of a cut is possible to take in each particular case is the black magic that separates beginners from seasoned pros.

Not to worry though

Here is an example ...
...Read More


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