Certain elements are needed for successful entry into the adaptive machining arena. First is proper tool selection and tool balance. With higher feed rates, the tool in question must have a relief angle that is neither too high nor too low. Another issue is adjusting for radial and axial chip thinning. Due to chip thinning, a series of calculations must be taken to determine the adjustment to the feed rate. A final element of high speed cutting relates to toolpath strategy. The proper adaptive toolpath uses a radius motion to gently move the tool in and out of the cut. The larger the tool, the greater the radius.
- Make sure that the setup permits chip evacuation no matter if the relief is moderate, high, or weak. Otherwise there will be no usable tools no matter how high or low grade material tools are made.
- Chip thinning can either decrease or increase the surface and cutting diameter of tools used to finish an item. The less usable cutting diameter the higher the loss of valuable materials wasted.
- Traditional tool making is slower but predictable in creation. New technology relies on calculation and formulas key to making adaptive machinery work efficiently.
“Too little relief angle results in rubbing at high feed rates that causes rapid heat buildup and tool failure.”