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AE-TL-N DLC Coated Carbide End Mill Drives Greater Efficiency in Aluminum Part Processing

Frank Twomey | OSG USA

Founded in 1968, Ross Industries, Inc. is a specialist in food processing and packaging solutions. Some of its key products include meat tenderizers, antimicrobial intervention systems, chilling and freezing equipment, formers and presses, slicers, macerators, tray sealing equipment, and more. All Ross systems are designed to help processors streamline food manufacturing and packaging functions to improve quality, productivity, and food safety while minimizing waste. With more than 50 years of industry expertise, Ross Industries has built an international reputation as one of the world’s finest food processing and packaging system providers. Employing approximately 100 staff, Ross Industries’ manufacturing plant is located in the city of Midland, Virginia, USA, with an estimate production area of 80,000-square-feet.

Founded in 1968, Ross Industries, Inc. is a specialist in food processing and packaging solutions. Employing approximately 100 staff, Ross Industries’ manufacturing plant is located in the city of Midland, Virginia, USA, with an estimate production area of 80,000-square-feet.

Recently, Ross Industries was tasked with reducing cycle times on all of its aluminum parts. OSG Territory Sales Manager Frank Twomey has been in touch with Ross Industries through a distributor for about two years ago. In need to optimize productivity, OSG was given with an opportunity to test cut the upper chamber 6061 aluminum alloy part used in Ross Industries’ tray sealers for food packaging.

A CAD model of the front & back of the upper chamber, a part used in Ross Industries' tray sealers for food packaging.

Ross Industries has been producing these aluminum upper chambers for more than 25 years. Approximately 80 chambers are made annually along with thousands of other aluminum parts. The upper chambers are machined using a Doosan HM 1000 horizontal machining center with CAT-50 spindle taper.

The upper chambers are machined using a Doosan HM 1000 horizontal machining center with CAT-50 spindle taper.

Ross Industries was originally using a competitor 1.5-inch diameter indexable shoulder cutter for the application. The competitor tool was used at a speed of 6,000 rpm (2,358 sfm, 717.8 m/min), a feed rate of 120 ipm (3,048 mm/min), 0.005 ipt (0.127 mm/t), 0.3-inch (7.62 mm) radial depth of cut, 0.375-inch (9.525 mm) axial depth of cut, and at a metal removal rate of 13.5 inch3/min (221.2 cm3/min).

The upper chambers are made of 6061 aluminum alloy.

Upon a detail evaluation of the application, Twomey recommended OSG’s 3-flute 1-inch diameter AE-TL-N DLC coated square end mill (EDP# 86301809). The AE-TL-N DLC coated carbide end mill is extremely effective for non-ferrous materials such as aluminum alloys that require welding resistance and lubricity. With excellent cutting sharpness, it is able to suppress burrs to achieve superb surface finish. The AE-TL-N features a unique flute form to enable trouble-free chip evacuation and a large core design for high rigidity to prevent chattering. Its center cutting edge configuration enables the tool to be used for plunging. Furthermore, with the addition of OSG’s DLC-SUPER HARD coating, long tool life can be achieved. This end mill series is available in square, sharp corner edge and radius types to accommodate a wide range of applications.

The AE-TL-N DLC coated carbide end mill is extremely effective for non-ferrous materials such as aluminum alloys that require welding resistance and lubricity.

The AE-TL-N DLC coated carbide end mill was tested at a speed of 5,125 rpm (1,343 sfm, 408.7 m/min), a feed rate of 231 ipm (5,867 mm/min), 0.015 ipt (0.382 mm/t), 0.14-inch (3.556 mm) radial depth of cut, 1.62-inch (41.148 mm) axial depth of cut, and at a metal removal rate of 52.39 inch3/min (858.5 cm3/min). Cycle time on the upper chambers went from 34.5 hours to nine hours.

By switching to the AE-TL-N, Ross Industries has reduced about 75 percent of cycle time on the upper chambers and is now on average achieving a 150 percent cycle time reduction on other aluminum parts.

By switching to the AE-TL-N DLC coated carbide end mill, cycle time on the upper chambers went from 34.5 hours to nine hours.

“This end mill creates chips so fast that our machines chip conveyors couldn’t keep up,” said Ross Industries Machine Shop Manager Greg Williams. “We had to speed up the conveyors.”

Taken in consideration of factors such as tool change time, machine cost, labor, etc., it is estimated that an annual cost savings of $183,000 can be gained. In addition to the upper chamber part, Ross Industries has also converted all of its aluminum end mills to OSG’s AE-TL-N series in various sizes.

From left, Ross Industries Machine Shop Manager Greg Williams and OSG USA Territory Sales Manager Frank Twomey pose for a photograph with a completed upper chamber.

“With the performance and consistent tool life of the AE-TL-N we are able to run these tools lights out,” said Williams. “In some cases, it is able to achieve as much as four times the metal removal rate versus the competitor tool.”

For more information on OSG’s AE-TL-N DLC coated end mill for non-ferrous materials and Ross Industries

VGM End Mill Boosts Productivity and Lowers Cost Per Part in Aerospace Bracket Application
Sean McIntosh, OSG USA

Founded in 1951 in Phoenix, Arizona, United States, Allied Tool & Die Co. is a family-owned precision machine and fabrication company that specializes in the manufacturing of quality parts for aerospace, medical, communications and commercial industries throughout the world. Seventy years since its establishment, this privately owned shop has grown with multiple facilities and an estimated 32,000 square feet of manufacturing space in Phoenix, Arizona.

One of the challenges Allied Tool & Die faced recently was the machining of aerospace brackets made of Inconel 718. As is with most shops, machining Inconel 718 is time consuming. Moreover, due to the material's special high strength and heat resistance properties, short tool life is a common obstacle.

In search for performance improvement, Allied Tool & Die CNC Process and Machining Manager Jamie Lerma reached out to his local OSG representative for new solutions. Lerma had worked with OSG previously on a 13-8 stainless steel application by utilizing OSG's HY-PRO® CARB VGM series end mill to achieve high-efficiency milling.

OSG's HY-PRO® CARB VGM is a high performance variable geometry end mill series. Its variable index and unique flute geometry enable the reduction of vibration and chatter, promoting smooth and stable cutting with low cutting forces. With the addition of OSG proprietary multi-layer EXO coating, higher wear and heat resistance is achieved to prolong tool life. OSG's VGM offering features 5-, 6- and 7-flute lineups, and is available with multiple lengths of cut, with both square end and corner radius variations. This series is suitable for carbon steels, alloy steels, die steels, stainless steels, cast iron, nickel alloy, titanium, and hardened steels up to 45 HRC.

For the 13-8 stainless steel application, the VGM end mill dominated the machining result by extending tool life from seven parts to 21 parts per tool. The parts were also completed in half the time and the tool cost is also cheaper than the competitor tool. Lerma was so impressed by the VGM end mill that he decided to apply the tool to the Inconel 718 aerospace bracket application.

Allied Tool & Die was previously using a high feed indexable milling cutter for the Inconel 718 aerospace bracket application. However, the amount of time and money spent on changing the inserts was less than desired. The previous competitor tool was used at 150 SFM (45.7 m/min),0.009 IPT (0.23 mm/t), 0.05 Aa (ap = 1.27 mm) and 0.75 Ar (ae = 19.05 mm). After reprogramming to utilize OSG's 0.5-inch diameter 5-flute VGM carbide end mill with a 0.030-inch (0.762 mm) corner radius and 1.25-inch (31.75 mm) length of cut (EDP# VGM5-0143), the cutting parameters were changed to 250 SFT (76.2 mm/min,
2,548 min'1), 0.0022 IPT (0.056 mm/t,713 mm/min), 0.75 Aa and 0.035 Ar. The application went from a 4-hour cycle time to just one hour and 45 minutes. Allied Tool & Die no longer had to keep stopping the machine to rotate or change inserts, which they were doing four times per part previously. By switching to the VGM end mill, the tool was loaded, and the job did not have to be tended to until the part was completed. In terms of efficiency improvement, Allied Tool & Die estimated that the tool change has generated a cost savings of $6,875 USD on the Inconel 718 aerospace bracket parts. Moreover, with a lower tooling price versus the previous milling cutter, the cost of tooling also decreased by almost $100 USD per part. With the VGM end mill, Allied Tool & Die was able to machine Inconel 718 at an astounding 250 surface feet per minute (76.2 m/min)- a speed that is only commonly seen in
alloy or stainless steels, not HRSA materials.

With the recent successes, Allied Tool & Die's CNC Programmer John Hernandez decided to apply the
VGM end mill into most jobs he programs. Being such a versatile tool, the VGM can be used to machine anything from common carbon steels up to the nickel alloys required by the aerospace industry.

"This VGM end mill saved us a ton of time," said Allied Tool & Die CNC Process and Machining Manager Jamie Lerma, who has started ordering the VGM series end mill to keep in inventory for whatever job comes up.

Learn more about OSG's HY-PRO® CARB VGM end mill here

1. A CAD/CAM model of a part made from 13-8 stainless steel. Image courtesy of Allied Tool & Die.

2. A CAD/CAM model of an aerospace bracket made from Inconel 718. Image courtesy of Allied Tool & Die.

3. A part made from 13-8 stainless steel that was machined by OSG's HY-PRO® CARB VGM end mill

4. An aerospace bracket from Inconel 718 that was machined by OSG's HY-PRO® CARB VGM end mill

Introduction

Working with CNC machines that are not precise and versatile can make the machining process challenging. For this reason, engineers opt for non-cut-and-dried vertical milling machines. However, that does not necessarily mean that selecting any CNC machine cutting tools is restricted to how well they perform in terms of accuracy and precision.

One needs to be mindful of several factors when selecting such tools. Failure to do so may result in a poor-quality end product that no manufacturing unit wishes to produce.

Here are five important considerations when selecting CNC cutting tools. Take a look. 

1. CNC Machining Tool Configurations

A CNC machine features different configuration types. Many CNC machining tools offer multiple features. In other words, many CNC tools can be configured for multiple tasks to be handled by a single cutting machine. This feature further reduces the time needed to complete the entire machining process.

Multi-feature CNC machines can also save considerable time, which may go into changing the tools for different requirements. However, it should be noted that different configurations are designed for different workpiece types and materials. Thus, engineers must know which tool configuration they need for their workpieces.

2. Materials And Features Of The Workpiece

The tool to be used is highly dependent on the material of the workpiece one is operating on. Experts recommend different CNC machining cutting tools for different material types. For example, the Stecker machine works with aluminum, grey iron castings, and ductile iron.

Even within these materials, aluminum tends to have the highest machinability and SFM (surface feet per minute). Therefore, engineers and manufacturers should understand the materials and features of their workpieces.

3. The Capacity of CNC Machines

Tooling machines should be shortlisted depending on the production volume of one's projects. CNC machines can use the majority of cutting tools. However, that does not equate to the enhanced efficiency of those CNC machines. Experts recommend that a higher horsepower machine allows engineers to use multiple combo tools suitable for performing various functions.

In addition, the casting of the machine is also an important consideration. Case in point: smaller castings do not require the help of hosts to move them around, unlike large castings. Running multiple tool parts on a pallet can save considerable time that may go into changing the tool parts.

In other words, selecting the right cutting tool is all about matching the machine's ability and availability to the requirements of projects.

4. Materials Used in the Cutting Tools

Engineers have to work with different materials as per project needs. One must note that the materials used for designing cutting tools can enhance the longevity and finishing of the end product. Case in point: some cutting tools can be developed using materials that are more durable than others. Most cutting tools are made of solid carbide because solid carbide creates a durable cutting tool.

However, polycrystalline diamond-tipped (PCD-tipped) tools can create the hardest and the most reliable cutting tools. It is worth noting that the tool life for a drilling tool made from PCD is around four times longer than that of ones made from solid carbide. The PCD-tipped tools are also known to be 25 times faster than the carbide-cutting tools. In addition, the precision of the PCD-tipped tools is also better.

However, one of the important points to be wary of when selecting materials for cutting tools is the cost. While PCD-tipped tools may seem like the best option for cutting high-precision edges, they come with an expensive price tag. Thus, solid carbide is a less expensive option that costs 75 times less than PCD-tipped tools.

5. Feed and Spindle Speed

The feed and spindle speed are two technical terms that one needs to understand to create better end products. Feed speed is technically the rate at which the work material moves inside the cutter. Feed speed is always dependent on the spindle speed. Failure to use an accurate feed and spindle speed can even burn the workpiece.

Engineers must mathematically determine the optimal feed speed before operating on the workpiece to avoid unwanted results. It is important to note that feed speed is not the same as cutting speed, which is the peripheral speed of the tool. In other words, feed speed is associated with the movement of the cutting tool, while cutting speed is associated with the tools.

Conclusion

Engineers tend to work with designs with higher geometric complexity and different materials. As a result, it goes without saying that when working with computerized cutting tools, accuracy is the utmost priority. However, the tool's accuracy is not the only aspect that makes or breaks the efficiency of CNC machining processes.

One needs to be mindful of various aspects before deciding on the right tools for precise cutting. Awareness of the aforementioned factors is essential to enhance the efficiency and end product.

About the Author:

Vincent Hua

Vincent Hua is the Marketing Manager at TSINFA. He is passionate about helping people understand high-end and complex manufacturing processes. Besides writing and contributing his insights, Vincent is very keen on technological innovation that helps build highly precise and stable CNC Machinery.