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Thoughts on FSWizard Future

December 18, 2012, 1:59 am by Eldar Gerfanov

Where do we stand and how did we get here.

When i first started FSWizard project one year ago in December 2011. I felt the need to upgrade my knowledge and skill-set regarding speeds, feeds and best cutting conditions.

Other calculators available at that time simply did not cut it for me.

One of them did not account for such important parameters as tool length.

The other did not care about such crucial tool geometry features like helix angle, shank diameter, lead angle and so on.

As a result i have endeavoured on a mission to build the best calculator that would accurately predict cutting forces, cutter deflection and suggest best cutting modes using all available tool data for multitude of combinations of work-piece/tool materials, coatings and tool types.

It has been a year of research, building cutter and material models, applying REAL MACHINING experience.

All results were tested in REAL PRODUCTION environment.

Today thanks to FSWizard, machines i work on produce 200%-300% more parts per day than 1 year ago.

It has been one year since i have started.
And i believe i have achieved my original goal.

Today The FREE FSWizard gives far better results than many expensive solutions available on the market.

FSWizard:Standalone is the only available program that will warn you if cutter will be reaching its breaking point.

In fact we see paying users of other programs asking their developers for features that have been long implemented in FSWizard.
And we see those developers finally moving out of their comfort zone and trying to improve their program's functionality.

Where do we go from here?

What does the future hold for this project?

No one really knows.
Unlike others who can talk the speed/feed game, I am not into marketing.
I don't do a particularly good job of persuading people that my product is the best thing that happened to the CNC world.

All i have is 2 hours of free time on my hands after work and a ton or real-world machining experience not many in the software business can brag about.

All that remains to say here is

I am not using words "product" ,"consumers" and "business" just by accident.

Next release version of FSWizard:Standalone 0.015 PRO will be a commercial product.

It will be sold as a 1 year subscription.

I am not yet sure about the pricing.
But i know that i will make it subscription-based and the price will be very affordable.

This is the only way to move forward on this.

If you have any comments or thoughts, i would love to hear them out.

 

 


FSWizard:Standalone News!

December 11, 2012, 7:51 pm by Eldar Gerfanov

Download link to the standalone version has been removed ahead of a major release planned this month.

We have decided to not keep a version vastly inferior to the next one available for download any longer.

Sorry and check back in a short while.


New Support Forums

December 11, 2012, 9:02 am by Eldar Gerfanov

After quite a few requests i have finally created support forums to address suggestions/bugs and problems regarding FSWizard

Please submit all your requests in the appropriate sub forum over here http://zero-divide.net/index.php?page=forums

 


Pictures of Nested Parts

December 9, 2012, 6:10 pm by Eldar Gerfanov

Here are some samples of nested parts i did recently

In both cases back of all pieces were machined at the same time, dowel holes milled so that there would be a way to align top and bottom.

Ealot of material was lost, but it was a scrap anyways, so all i gained was alot of saved man-hours.

Photobucket

And here are 4 more pictures:

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New web site layout

December 9, 2012, 4:11 pm by Eldar Gerfanov

So how do you guys like it.

Give me a shout!


Advantages of using Hi-Helix endmills

November 24, 2012, 12:25 am by Eldar Gerfanov

Hi-helix end mills have several advantages inherited with their design.

Simple math says that a an endmill with 45 degree helix angle directs 50% of the cutting force downward versus  25% for a 30 degree end mill.

Main advantages are:

  • Higher rake angle directs more of a cutting force downward.
    This reduces side load on the cutter, that leads to less deflection and less tendency to chatter.
  • At high axial engagement (deeper depths of cuts) more flutes remain in the contact with the work piece. This leads to much smoother cut, again reducing tendency of the cutter to chatter.
  • High helix angle pulls chips upward and away from the cutting zone.
    This reduces chip re-cutting and helps prevent cutter from getting clogged up. This also allows to take deeper cuts and increases productivity.
  • Because of higher helix more of flute length is being used in the cut. Better surface finish is achieved even when using the same chip load.
    Generally an end mill with 45 degree helix can be fed 30% faster than equivalent one with 30 degree helix and still achieve same surface finish.

 

High helix end mills also have disadvantages that a machinist has to take into consideration:

  • With more of cutting force directed axially, the load on spindle bearings in downward direction is increased.
  • Tendency for both the end mill and the work piece to pull out is increased. So a more rigid tool holding and work clamping should be considered.
  • Higher helix end mills are also less stiff that regular helix end mills. This may cause more deflection and may become a problem when having to machine straight walls.
    This effect should be mostly diminished by lower side radial load, but it still needs to be considered in some cases.

Famous Quotes/ Deep thoughts

November 23, 2012, 11:21 pm by Eldar Gerfanov

Just decided to store here the quotes that i liked.

And those that made me think about purpouse of life and Univerce.


FSWizard:Stanadalone

October 26, 2012, 8:30 am by Eldar Gerfanov

The ONLY FREE CNC Speeds and Feeds Calcualtor

Confidently calculate cutting conditions for hundreds of work-piece materials and of combinations of tooling types and coatings.

  • Accurately Estimate cutting forces involved in machining process and prevent tool breakage.
  • Estimate machine power requirement and help choose best tool for the job.
  • Suggest safe and practical Axial and Radial engagement values.
  • Compensate for reduced-shank, long and extra-long tools.
  • Improve cycle times and tool life
  • UNIQUE feature that allows to set comfortable levels of cutter torque and deflection and prevent cutter breakage.
  • Ideal for use as your Dynamic / Thoroidal / Truemill calculator

Please visit the project page for download link, support and instructions.
http://zero-divide.net/index.php?page=FSWizard_SA

 


What to do when you can not clamp it

September 28, 2012, 12:51 am by Eldar Gerfanov

If you cant, then dont clamp it at all!.
Skin it!

In here i have to program and machine several sets of roundish aluminum pieces with +/-0.001" outside tolerance. and within 0.002" thickness repeatability.
Instead if fixturing it one by one i decided to skim cut a 33" x 23" x5/8" to within 0.0015 flat. And then machine each piece completely leaving .005" outside to holt everything together.

Worked out great. 

for pics...
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Shop-made indexing fixture

September 28, 2012, 12:32 am by Eldar Gerfanov

Needed to do alot of side drilling/milling/tapping on our moulds lately.

So I quickly designed and whipped up this custom indexing fixture that allows me to mount almost anything to it.

Face plate has several tooling dowel holes on front side to locate work piece.
On the back of face plate there are 36 3/8 dia reamed holes spaced 10 Degree apart.

Housing has a big 5.0"Dia pocket in the front into which the face plate's hub fits in with 0.001" clearance
Housing also has corresponding 3/8dia reamed holes spaced apart 9 degrees. This allows me to index the face plate with 1 degree increment.

Design time:2 hours, Machining time: 2 hours.

Pictures are here:

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