"Challenge us to help you do what you do more effectively." Those were the words of Ingersoll Cutting Tools President Chuck Edler as he kicked off the Die & Mold Seminar yesterday, which honed in on understanding the precise tools necessary for the delicate processes of mold manufacturing--milling, high-volume roughing, high-feed roughing, aluminum machining, gun drilling and hole making to name a few.
Some takeaways included:
- Optimizing millling by examining its three forces: tangential, axial and radial (the latter being the one causing the most trouble).
- You want the chip to move not the part.
- Control the forces.
- Understand deflection and rigidity.
- Understand chip thickness to help maximize tool life and minimize cycle time.
- If milling steel, don't use coolant.
- Understand the cusp that's left. Cusp is important for moldmaking because of surface finish. Reduce cusp height.
- Constant chip load is key to achieving big gains in machining productivity.
- Leverage your technology.
Technology highlights included the Form-Master Shear--excellent for those aluminum prototype molds; the Form-Master Speed--for high-feed roughing and plunging; and, the U.S.-designed "champion" Hi Quad F--whose four cutting edges with a choice of eight different cutting edge geometries, ensures long tool life even under the most demanding applications across the widest range of materials.
See them all in action here.