Today’s tool-life management systems provide several benefits for companies that have long production runs. Primarily, they enable users to place multiple, identical cutting tools in the machine and will automatically select another tool in the group when one is dull. 

Another feature of such tool-life management systems is their ability to automatically make sizing adjustments. To use this feature, however, the user must first determine the appropriate frequency and amount of each sizing adjustment for a given cutting tool. Even though sizing adjustments are only required for finishing tools (so there won’t be many tools that require sizing in a given job), it can still be difficult to acquire the needed data. For this reason, many users do not utilize this automation feature at all.

Admittedly, manually tracking all sizing adjustments an operator makes during each finishing tool’s life can be time-consuming and prone to error. But if we can accurately determine the trend for each tool, we can, in turn, program the sizing adjustments and completely eliminate the need for the operator to perform this task. Programming these adjustments could be done using the tool-life management system or with a custom macro.

Here, we offer a way to automatically track sizing adjustments for turning centers. This can be used over the course of several dull-tool replacements, so that you can get the trend data you need to program automatic adjustments. 

At the end of each cycle, call the custom macro to see if any offset adjustments have been made:
O0001 (Machining program)
G65 P9110 (Call the custom macro)
M30

If none of the offsets have been changed, no data will be recorded. If an offset value (X or Z) has been changed, the custom macro will use the DPRNT command and output the current part count, the tool station number and the amount of the adjustment. A printer or computer connected to the machine’s communications port will receive and print/store the data. You can use this method to track offset adjustments for as long as it takes to develop accurate trend data.

Here is the custom macro:
O9510 (Track offset changes)
#500=#500 + 1 (Step part counter)
#100=1 (Current tool station number)
#101=12 (Number of tool stations to monitor)
N5 IF [#100 GT #102] GOTO 99 (Test if finished)
(Test X register of offset)
IF [[#[2000 + #100]] EQ [#[510 + #100]]] GOTO 25
(Test for change to offset)
(X offset changed):
#1=#[2000 + #100] – #[510 + #100] (Change amount)
DPRNT[PART*NO:*#500[50]***TOOL*NO:*#101[20]***OFFSET*CHANGE:*#1[14]]
#[510 + #100]=#[2000 + #100] (Set change tester to new offset value)
N25 (X offset not changed)
(Test Z register to offset)
IF [[#[2100 + #100]] EQ [#[530 + #100]]] GOTO 50
(Test for change to offset)
(Z offest changed):
#2=#[2100 + #100] – #[530 + #100] (CHANGE AMOUNT)
DPRNT[PART*NO:*#500[50]***TOOL*NO:*#101[20]***OFFSET*CHANGE:*#2[14]]
#[530 + #100]=#[2100 + #100] (Set change Cemented Carbide Inserts tester to new offset value)

N50 (Z offset not changed)
#100=#100 + 1 (Step counter)
GOTO 5
N99 M99

Prior to running the first workpiece, the value of permanent common variable #500 must be set to zero to reset the part counter. This can be done by commanding #500=0 in manual data input (MDI) mode or by setting #500 to zero on the variable display screen page.

For 12 tools, the custom macro uses permanent common variables #511 through #522 for X, and #531 through #542 for Z to monitor the current offset settings. Each time the custom macro is executed, this data is compared with the related offset data. If a change has been made, the DPRNT command is given and the value of the permanent common variable is set to the related offset value. This means the first set of DPRNT commands will not be correct, as each permanent common Carbide Grooving Inserts variable is set to the initial offset settings. Accurate monitoring will begin with the second workpiece.

When an offset value changes, the custom macro will send a message like this:
PART NO: 00053 / TOOL NO: 03 / OFFSET CHANGE: -0.0007

After running production for several hours, days or weeks, you will have accumulated the trend data you need to know when sizing adjustments must be made for your finishing tools.

The Carbide Inserts Website: https://www.estoolcarbide.com/pro_cat/deep-hole-drilling-inserts/index.html

The TC L 3050 from Trumpf Inc. is equipped with the TLF 6000, a 6,000-W CO2 resonator that is designed to increase cutting speeds by as much as 29 percent.

The laser cutting machine is integrated with linear drive technology and has the capability to perform at speeds as high as 1,900 ipm when processing thin sheets. When used in conjunction with the 6,000-W laser, the system can cut material as thick as 1′ (mild steels and stainless steel) and 5/8′ in aluminum.

Also included is a cutting feature that can reduce positioning times while increasing productivity by as much as 70 percent in certain applications; the company’s process control system, which monitors and adjusts laser parameters to cemented carbide inserts improve pierce hole quality and reduce pierce time; and Sprintlas, on-the-fly piercing that punches through material as thick as 1/4".

Autolas, the company’s programmable focus system, the Dias capacitive height sensing, deep hole drilling inserts and four quick-change cutting heads allow the laser user to go from thin sheet cutting to thick plate cutting.?

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The Carbide Inserts Website: https://www.aliexpress.com/item/1005005874290728.html

Walter’s Tiger-tec Silver turning inserts are designed to reduce machining times and increase process shoulder milling cutters reliability, particularly in steel turning applications, the company says. The Tiger-Tec Silver CVD coating is said to increase productivity while extending tool life. The inserts are suitable for use with unalloyed and alloy steel, cast steel, stainless ferritic and martensitic steel, as well as ductile cast iron.

Of the three grades, WPP10S offers the highest temperature resistance and hardness. gravity turning inserts It is wear-resistant and suitable for processes ranging from continuous cutting to minor interrupted cuts at very high cutting speeds. WPP20S, the medium grade, is suitable for use as a universal cutting material for processes ranging from roughing to finishing. WPP30S maximizes reliability for difficult applications such as interrupted cuts and unstable conditions.

Four geometries are also available. For facing and light cuts, the FP5 geometry is said to provide reliable chip control during turning operations from 0.008" depth of cut. The MP3 geometry is suitable for medium machining, the versatile MP5 geometry is specifically designed for general machining and the RP5 geometry is designed for roughing.

The Carbide Inserts Website: https://www.aliexpress.com/item/1005005925592551.html

Arch Cutting Tools has hired Charlie Novak Jr. as business development coordinator for the company’s Arch Specials business. In this role, he will develop the cooperative efforts of cutting tool business units BTA deep hole drilling inserts supporting Arch Specials, put to work his applications and sales skills filtering Arch Specials RFQs, provide gatekeeping to internal gravity turning inserts quotation routings, and support sales staff. 

Mr. Novak has experience in design and production of tools as well as customer-facing roles with applications and products. He comes to Arch from Fives Landis – Citgo Diamond, where he most recently spent seven years as product manager of PCD/CBN cutting tools and grinding wheel and wheel dressing products, as well as overseeing R&D and new product development. 

Prior to Fives Landis, Mr. Novak spent seven years with Competitive Carbide (Arch-Mentor) as a custom cutting tool CAD designer, and then in manufacturing in CAM/CNC Programming.

The Carbide Inserts Website: https://www.aliexpress.com/item/1005005904572323.html

BobCAD-CAM is a software developer that has offered affordable, intuitive CAM packages for two- and three-axis machining applications for nearly 30 years. The company recently worked with ModuleWorks, an Aachen, Germany CAD/CAM component supplier, to support customers looking to perform more complicated work such as simultaneous five-axis machining. The result is BobCAD/CAM’s new Version 25 Four- and Five-Axis Mill software packages that enable it to offer a single programming platform for an increasing base of customers that are integrating higher-end equipment.

One way users can benefit from these packages is by performing four- and five-axis simultaneous roughing operations. Traditional approaches (even when a four- or five-axis machine is used) complete much of the roughing using three-axis movements. This not only leaves behind stair steps that must be cleaned up with subsequent operations, but extends programming time. Conversely, simultaneous four- and/or five-axis roughing tool gravity turning inserts paths can be much more efficient than a series of three-axis roughing with part indexing routines followed by clean-up of the additional stock left behind.

However, a new multi-axis tool path available in BobCAD-CAM’s four-and five-axis packages makes such simultaneous, multi-axis roughing routines even more efficient. Adaptive Roughing applies the consistent-tool-engagement-angle strategy that previously has been only available for two- and three-axis operations to four- and five-axis simultaneous movements.  The company says it is the first to provide a consistent-tool-engagement-angle toolpath strategy for two through five-axis operations.

Adaptive Roughing uses arcing, trochoidal movements to maintain a consistent load on the tool. This differs from conventional tool paths that base the feed rate on cutting conditions whereby the tool is under maximum Carbide Milling Inserts load (such as when a tool is driven into the corner of a pocket, a situation when the angle of engagement with the material is much higher than with a straight-line cut.) Maintaining a consistent tool engagement angle means the programmer doesn’t have to base the feed rate of an entire tool path on that type of worst-case scenario. The result is a faster feed rate, more consistent tool wear and the full use of the tool’s length.

Applying this concept in four- and five-axis movements is useful for pockets with a floor that bends or wraps around a cylindrical surface (see the screen shot on the previous page). It essentially morphs a consistent-tool-engagement-angle tool path between the floor and ceiling of a pocket. In addition to pockets, this strategy might be promising for select moldmaking applications.

Adaptive Roughing is just one of many toolpath strategies offered in the company’s four- and five-axis software. Others include a true swarf machining tool path as well as a variety of surface-based tool paths. The software offers 100-percent-associative tool paths and supports multi-core CPUs to reduce the calculation time of complex tool paths. Plus, the company supplies postprocessors with every seat of software.

The Carbide Inserts Website: https://www.estoolcarbide.com/product/factory-wholesale-cnc-lathe-cutting-tools-solid-carbide-inserts-milling-inserts-bdmt11t308er-jt/