Maching test matrix

[jmossbarger]

Hello guys, first post to this forum, hopefully someone can help me out. We are looking to develop new machining processes for a new material we are using. We are focusing on turning operations and would like to test various inserts, coolants, coolant pressures, feeds, speeds, etc. The goal is to obtain a balance between tool life and cyle time (as is just about everyone's goal!).

What I am looking for is a template that someone might have used for a similar project. I did some searching for setup sheets, but they don't lend themselves to various changes. This might be a spreadsheet, database, word document, etc. I am just looking for a good way to document the test and help with making the results clear.

Thanks in advance!
Joe

 

[tripleZ]

Pick up a textbook that has a chapter or more on "Design of Experiments" and more specifically, multifactorial experiment design. First, it'll give you template ideas (you'll probably have to create your own based on what you want to measure). Second, reading about experiment design will help you develop a logical way to test the parameters you want to test, hopefully without overtesting or undertesting.

If you already know this, I'll shut up and go back to tool design...=)

 

[jmossbarger]

Thanks triplez, but yes, I am familiar with the DOE side, but I am looking for a good way to document the various settings in more of a database or spreadsheet format, where more information can be detailed.

thanks,
Joe

 

[jck26]

Joe, this is a complex question to answer. I did lots of cutting tool testing in school and industry. You need to ask the question what defines the life of the tool? Is it failure to cut or surface finish requirement. Most would not want to use failure as the mode and surfcae finish is the most sensitive to all factors thus giving in many cases the shortest life.

If you want to get up and running fast call 3 tooling vendors and give them the challenge of your process. These guys are excellent. Our inhouse Kennametal guy can get us very good pereformace on the first tool attempt. These guys will be able to advise you as you tune the process.

To do exhaustive work looking at flank wear, crater wear and mode of failure are all noble efforts but most companies are not that focused on metal cutting. I have done work where, as part of the duties of manufacturing engineering, we had an on going program looking at tool life issues across the whole plant. We were constantly upgrading our tooling. We looked at simple factors like parts per edge in our comparisons. Every operation was evaluated as to the speed and feed to see if we could creep these parameters up.

Additionally you can do the coolant testing in the same manner. My personal view of coolant is that it over looked in terms of application to improve performace. I like lots of coolant volume through coolant feed tools and I make sure that the operators are applying it at the right spots. I'm not opposed to running dry, we do it in aluminum with PCD tooling, but mostly we run with water based coolants.

jck26

 

[tomwalz]

I’ll second jck26.

1. Test form - see #1 below
2. Work your vendors - #2 below
3. Coolant management - # 3 below
4.

http://www.practicalmachinist.com

1. Work your vendors. At

http://cs4u.org/testform.htm

is a test form we supply for people who want to test new materials in sawing applications. A good vendor should understand most of the parameters that exist in your operation.

2. Work your vendors. Most of our customers prefer to profit by the experience of others rather than do their own research if it is at all possible. A good vendor should be able to tell you about other users by name and phone number. Then you can call the other users.

3. Coolant management – I think that improper coolant maintenance is a much greater problem than which coolant is used. See

http://www.cuttingtoolengineering.com/pdf/0205-fineideas.pdf

4. American Machinist has a discussion group. There are a bunch of guys there that are really good.

Tom


Thomas J. Walz
Carbide Processors, Inc.

http://www.carbideprocessors.com

 

[limct]

making use of Factorial DOE featured in statictical tool will be good for your decision making and documentation.

Best regards,
ct

 

[toolmantwo]

I have done this before with success and you might find some great facts.

I used a spreadsheet. I logged in the type of insert used and how long (Number of parts) before it would either fail to cut or the cut was too rough or the insert would break.

I also found out that more coolant in more places made a big difference. Example if the chip curl and or buildup on the tool stopped the flow of the coolant, we went to more ports and more angle of attack with the coolant to solve.

I also tested inserts that did better, and then met with the supplier of the inserts with my data to see what insert type to try next. In my case we wanted more parts per tool, yet also wanted long tool life.

I can give more details if you still have the need. You might be done with this project by now.

Good luck, Toolman