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METALING AFFAIRS Gone Fishing ARE ALL THE DETAILS IN ORDER? by Andrew Skoog Machining is in many ways like fishing. You can really learn how to catch fish, due to the amount of time spent on the water going after them. Try another species and you have to learn their behavior, habitat, and the bait to use. Machining, if you always cut the same material in the same machine with the same tools you will get very good at it. Change materials, and the rules change with it. I thought for this article, I would write on a few technical topics that seem to come up frequently. Radius Selection As we run into difficult alloys, there are a few things that remain the same when machining various operations. The radius on an insert is a key factor in boring. Selection of nose radius is dependent on depth of cut, along with the feed. It influences the surface finish, chip breaking and insert strength. When the ratio of the depth of cut to the radius size is small, the resultant cutting force is radial and is trying to push the insert away from the bore surface. When depth of cut is increased, the resultant cutting force is changed to axial force. As a general rule of thumb, the depth of cut should be about 75 to 100 percent of the nose radius. Depths of cut smaller than 1/3 of the radius will result in stringy chips, deflection and/or chatter. Reduce the radius size when getting taper, for long reaches or to eliminate chatter. The generated surface finish will be directly influenced by the combination of nose radius and feed rate. Work Hardening Work hardening of materials is a condition that is caused when heat generated by the cutting tool transfers to the workpiece material. The process is similar to a heat treatment of the workpiece but on a lower scale. When a part work hardens during machining, its surface becomes a shiny glaze and appears slippery. When not recognized as work hardening, the tendency is to get defensive and reduce the feed—this magnifies the problem. Work hardening materials need sharp tools, light speeds, heavy feeds and high lubrication. How to avoid work hardening: Make sure the cutting tools are always sharp. Run at the recommended feeds and speeds. Use coolant-fed tools. (Lubricants should be mixed to the heavy side.) Use continuous feed, do not dwell tools. Avoid peck drilling. Built up edges on the cutting tool will cause intermittent work hardening. Broken taps may be the result of a work hardened hole. Maintained Coolant Many machine shop operators think of coolants as a necessary nuisance, something that blows chips off the part. In fact, the most important jobs for coolants are keeping the tool cool so it lasts longer, and lubricating the tool edge so that it makes a cleaner cut. When tool life suffers, operators start to look at switching cutters to find something that will give better results, when oftentimes, all they need to do is maintain their coolant concentration and levels. There are three basic types of coolants: soluble oil, semi synthetic (micro emulsion) and synthetic. When mixed, soluble oil is milky, semi synthetic is opaque, and synthetic is clear. Today’s coolants are a sophisticated mix of chemicals and additives that try to blend the best properties of oil into the best properties of water. Compounders who make these concentrates try to reach a balance of safety, rust inhibition, along with a tolerance of varied water types and the ability to work with many materials. There are three factors that are pushing shops to take a more serious look at coolants: increase in product cost, labor cost to maintain them and cost of disposal. It is possible to keep coolant working properly for years; you just need to understand how they work and why they go bad. Things you must do to maintain coolant, include keeping the sump full at all time, maintaining proper concentration, keeping chips out of the sump (they hold bacteria), and removing tramp oils (they feed bacteria). If your sump is smelly, the only way to have success with any future coolant is to properly clean the sump and the machine tool. Without doing this critical process, your refreshed coolant will go rancid prematurely. Properly cleaning the sump includes the following steps: 1. Kill the bacteria/fungus—usually an additive to the existing coolant 2. Pump out the old 3. Remove the food source for bacteria—clean the sump and the machine with a mild detergent 4. Rinse 5. Recharge the sump with fresh coolant 6. Bleed the lines 7. Maintain Properly maintained coolant will give your shop a pleasant atmosphere, years of service and aid in consistent tool life and surface finish. In machining, with all the details in order … you are in the fish! PM ANDREW SKOOG is with Hexis in Minneapolis, Minn. He can be reached at Andrew@hexpedite.com. 34 | PRECISION MANUFACTURING September | October 2012
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Page 1 and 2: SEPTEMBER / OCTOBER 2012 THE FUTURE
Page 3 and 4: FEDERATED® Your Association Does!
Page 5 and 6: CONTENTS September | October 2012 8
Page 7 and 8: MPMA EVENTS: SEPTEMBER Sept. 20 - 1
Page 9 and 10: COVER STORY Dream It. Do It. is a n
Page 11 and 12: MANUFACTURING MARVELS Election Ferv
Page 13 and 14: Bill Kuban: Legend and Legacy desig
Page 15 and 16: MADE IN MINNESOTA Tower Solutions S
Page 17 and 18: SHOP PROFILE “If you schedule reg
Page 19 and 20: INDUSTRY PROFILE: ENGINEERED FINISH
Page 21 and 22: WHEN NUMBERS MATTER: 6 NEW JOBS. 2
Page 23 and 24: FEATURE STORY Remember, MTConnect i
Page 25 and 26: BEST PRACTICES To solve this, Metal
Page 27 and 28: MANUFACTURERS’ MARKETPLACE A few
Page 29 and 30: MEMBER DIRECTORY Blanski Peter Kron
Page 31 and 32: MEMBER DIRECTORY IFS-Industrial Fab
Page 33: MEMBER DIRECTORY Stone Machinery, I

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