Cutting Tool Development: 25-Hour Timeline
Live Cutting Tool Development – A 25-Hour Timeline
- 10:00 a.m. – A customer shows up for a demo.
- 10:30 a.m. – In the machining lab, we discover the tool is cutting a gouge in the radius of the part. The tool has to reach into the part and cut a radius slot 12 mm deep. There are clearance issues that limit us to a 10 mm body on the tool.
- 10:45 a.m. – The tool is redesigned with a larger shank and a different flute configuration. While the tool is being ground on the CNC cutter grinder, we are in the machining lab on the other side of the shop readjusting the program, attempting to eliminate the gouge.
- 12:01 p.m. – The redesigned end mill is walked across the shop, delivered to us in the machining lab, and installed in the machine. After cutting the first slot, we discover that the gouge is still there. More test cuts are made to discover the root cause of the issue.
- 12:59 p.m. – We discover that, because of the long length of the tool, it is deflecting as we cut the rough pass, leaving a small gouge in the part. We also discover that the finish pass is hitting the back wall of the part, causing the tool to chatter long enough to gouge the part deeper.
- 1:30 p.m. – The machine is reprogrammed to accommodate the new cutter and shorten the z-axis cut by 0.2mm on the finish pass. This will prevent the tool from hitting the back wall.
- 1:42 p.m. – The end mill is sent back to the CNC cutter grinder on the other side of the shop for additional geometry changes to eliminate chatter.
- 2:22 p.m. – The tool is returned and installed in the machine.
- 3:30 p.m. – The testing begins to establish the final speeds and feeds for the process. The slot is being cut to the customer’s part print, and we have developed the final geometry and process for the application.
- 4:00 p.m. – Engineering releases the final prints to manufacturing. We will provide two sample tools for test at the customer’s office by noon tomorrow.
- 6:02 p.m. – We continue to test the process for any issues that may come up as the tool wears and start the final documentation process.
- 8:30 p.m. – Cutting tool prints are finished, along with the programming moves and speeds and feeds.
- 9:00 p.m. – The package is assembled to deliver to the customer. It includes a sample of finished parts, a complete set of tool drawings, a process print showing all the programming moves needed, pictures of the inspection process, and a video of the machining process at our plant.
- 11:00 a.m. – The customer receives the package with finished sample tools.
- 12:00 p.m. – The customer flies to their overseas plant to install the process and do a live test.
- 12:01 p.m. – The customer is excited to be invoiced because it saved them considerable time and money to solve the issue by working with Greene Tool Systems.
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