CNC TOOLING GUIDE - DynamiX SE

1 1-800-544-8436 CNC TOOLING GUIDE1-800-544-8436 CNC , GDP | GUHDO ,whichprovidethebasisforsafe, ,construction,engineeringexpertise,tothe balancingandinspectionofthefinishedprodu ct, , , :withoutthecuttingtool,yourmachinewon tproduceasinglething!INTRODUCTION1-800-5 44-8436 Cuttingtoolperformance, ,istheresultofasynergybetweencuttingtool ,clampingsystem,machinespindle,materialh old-down,efficiencyofdustextraction,corr ectmachiningparameters( ) , SYNERGY AT WORK1-800-544-8436 Keepinginmindthatahighclass,highperforma nceautomobilerequireshighquality,precisi on-balancedtirestorunsmooth, :.. ,highquality, GOOD ANALOGY1-800-544-8436 CUTTING TOOL OPTIONST hispresentationwillfamiliarizetheCNCnovi cewiththevarietyoftoolingsolutionsthatar eavailabletomeetspecificcutting,profilin g,drilling, ,propertoolselection,materialholddownand dustextractionwillincreasethefrequencyof thefollowingdesirableCNCcharacteristics: -Accuracy-WasteReduction-Repeatability-S pindleBearingsupkeep-FinishQuality-Botto mLineToolingCostUsingtoolswithinappropri atemachiningparameters,inparticular,corr ect chipload , ,chiploadisthesize/ ,goingfroma2flutebittoa3flutebit,thesize ofthechipisreducedby33%ifthefeedrateorsp indlespeed(rpm) !

2 Remember: Too big a chip load will decrease the small a chip will decrease the life. 1-800-544-8436 SAFETY ,ithasdevelopedveryextensivecriteria/nor msforthesafeandeffectiveoperationofmanuf acturingmachinery,cuttingtools, ,ANSI(AmericanNationalStandardsInstitute ), NORM abbreviation for DeutschesInstitutf rNormung(often just referred to as Deutsche Industrienorm) is the German national institute for standardization of almost criteriawithdetailssuchasminimumacceptab leshankdiameterbasedonthemassoftherespec tivetoolbodybeingmade,maximumknifeprotru sionbeyondtoolbody(oninserttools)andcoun tlessotherdetailsthatservetoprotectbothm achineoperatorsandthemachineitself, ,welooktoGermany sCNCmachiningcentersareequippedwithstate -of-the-artsafetyfeaturessuchascurtaingu ards,contactmats,guardfencingandmore,acu ttingtoolspinningat16,000+ with someone who meets the standard! 1-800-544-8436 TOOL HOLDERS AND CLAMPING SYSTEMS1-800-544-8436 CLAMPING SYSTEMS OVERVIEWFrom left clockwise1)Drill Bit Adapter 2)IS0/SK30/BT/HSK-F & E collet chucks3)Arbor Adapters for cutters/blades with bore4)Saw Blade Adapters1-800-544-8436 MOST COMMON CLAMPING SYSTEM HSK-F 63 DevelopedinGermany, , , , (Hohl-Schaft-Kegel), ,bothradiallyandaxially, INTERFACE ANATOMY (DIN 69 893)Clamping Jaw tensionedClamping Jaw relaxedTool HolderContact SurfaceCone FrustumClamping ConeClamping ShoulderClamping SegmentsPull BarDrive SpindleUnderstanding the inner workings!

3 1-800-544-8436 OVERVIEW OF MOST COMMON HSK-F 63 TOOL HOLDER STYLES FOR ROUTER TOOLINGS tandard Collet Chuck Hydro Chuck Heat Shrink Chuck PrezisoCollet Chuck 1-800-544-8436 ACCURACY OF THE DIFFERENT TOOL HOLDER STYLES:STANDARD CHUCK PREZISO CHUCKHYDRO CHUCKHEAT SHRINK *. HOLDER STYLES ARE INTERCHANGEABLE ON ANY MACHINE THAT HAS THE HSK-F 63 TOOL in 3 styles using either ER32, ER40 or RDO/SYOZ special RDO35 high precision colletsNo colletNo collet*depends on collet style used1-800-544-8436 COLLET STYLE AND RANGE TOLERANCERDO / SYOZ STYLEER STYLERANGE TOLERANCE (High Precision Version)RANGE TOLERANCE (Standard Version)RANGE TOLERANCE Colletswearout!Overtime, , ,soadheringtoacolletmaintenanceschedulei spreferabletocostlyrepairs. Cleancolletsandcolletnutswhenchangingtoo ls! Usepropertorque!Investmentinatorquewrenc htotightenthecolletnutisaprerequisitetoe xtendingtoollifeandreducingbreakage!

4 Payattentiontoclamptoolcorrectly!(seebel ow)Withpropertoolsetup,thecolletshouldbe filledto80% Replacecolletsevery500machinehoursforopt imumtoollife!Preventcostlyspindlerepairs !COLLETS -NOTEWORTHY INFO1-800-544-8436 COLLET NUTST hecolletnut,andaccuracythereof, (picturedinphotobelowontheright). (picturedontheleft) BearingStatic nut Bearing nut1-800-544-8436 Rigid tool stability Extremely high clamping force Saves expense of replacing collets regularly. Initial higher cost. Best for the Spoil Board (Fly) Cutter, all Insert Tools and Diamond Tools. Improved efficiencies over standard tool holders, increases tool life and improves finish. Not suitable for solid carbide tools and tools requiring frequent change since an additional investment in a heat induction unit is required. Saves expense of replacing collets regularly. Order Insert tools and diamond tools mounted on heat shrink chucks!

5 WHICH STYLE TOOL HOLDER TO USE?Forroutinemachiningofwoodandcomposit ematerials, ,theoptionofaPreziso PrecisionChuck,HydroChuckorHeatShrinkchu ckisagoodoption. Excellent choice to reduce vibration when cutting very hard materials Improved efficiencies over standard tool holders, optimizes tool life. Good choice to increase tool life with solid carbide spiral bits. No additional equipment needed. Excellent general use choice. This version is supplied with most new machines and adequate for general machining CHUCKPREZISO CHUCK HYDRO CHUCK HEAT SHRINK CHUCK 1-800-544-8436 CYCLONE DUST ,it , , (ontheleft)andtheother,withacyclonedustn ut(ontheright). ON COLLET REPLACEMENT First,click the collet into position by pressing only one sideThen, pushing down on the other side to lock it , TOOL ASSEMBLY1)Snap the collet into the collet nut or cyclone )Place the tool into the collet paying close attention to the proper tool depth in the collet.

6 Tighten the collet nut manually onto the tool )Position and secure the tool holder in a tool setup fixture as shown below. 4)Tighten the collet nut with a torque wrench to the correct torque based on the collet style StyleRecommended TorqueER 2059 ft/lbsER 32100 ft/lbsER 40130 ft/lbsRDO 35 (SYOZ25)90 ft/lbsSetup Fixture with Fixture (no gauge) and torque wrench1-800-544-8436 PROPER TORQUEI ncorrecttorquewhentighteningthecolletnut willresultinpoorcuttingperformance,prema turecolletwear, , t let this happen!Typical breakage pattern resulting from improper torque!1-800-544-8436 TOOL SETUP FIXTUREA setupfixtureandtorquewrenchareanecessary investmenttoachieveoptimumtoollifeThesea renecessarytoavoidtoolbreakage,inferiorf inish, , BITS AND ADAPTERS1-800-544-8436 USING DRILL BITS ON A , (withoutflat)togointothecollet, , Adapter1-800-544-8436 DRILL BIT SELECTIONF orholesthatwillgothroughthematerial,useV -PointBits(Thru-HoleBits) , ,thisbitisavailableinsolidcarbidein1/8 diameterForhingepockets, walking.

7 1-800-544-8436 CNC DRILL :WhendrillingorboringholesonaCNCmachine, Feedrate(m/min)3000 Feed / Speed for Drilling on CNC1-800-544-8436 SIZING, JOINTING, REBATES, DADO CUTS, AND GROOVING 1-800-544-8436 ThebestoptionsforCNCmachiningareeitherso lidcarbidebitorPCD(polycrystallinediamon d). PCDtoolingachievesthebestreturnoninvestm entwhenitisdedicatedtocuttinghomogeneous materialandnotinterchangedbetween,forins tance, ! Theonlytimeacarbide-tippedtoolisaneconom icalsolutionforuseonaCNCisforcuttingasma llprofiledproto-type( ).020040060080010001200 Carbide TippedSolid CarbidePCD (Diamond)TOOL LIFE COMPARISONTOOL LIFE COMPARISONSTRAIGHT ROUTER BITS TOOL MATERIALSCD1-800-544-8436 ROUTER BITSD ependingonproductandvolumebeingmachined, ,jointing,rebating,groovinganddados,theo ptionsavailablearesolidcarbide,carbidein sertorPCD(polycrystallinediamond).Forpro fileroutingapplications,optionsareeither carbideinsertorPCDandforproto-typeor one-off needs, , ,soresearchingcost, carbide router bits come in a variety of tool geometries, number of flutes, and edge grind to include the most popular ones below and described in more detail on the following pages.

8 O-Flute, Straight (Soft Wood/Soft Plastic) O-Flute, Up Cut (Plastics, Aluminum) Up Cut Ball Nose Up cut Down Cut Compression (Mortise Compression) Compression Chip Breaker Up Cut Chip Breaker Down Cut Chip Breaker Up Cut Rougher Down Cut Rougher Single, Two and Three FlutesSOLID CARBIDE BITSR emember: More flutes doesnot equal better finish!More flutes means you have faster feed rate capability! Refer to the chip load information later in this presentation to calculate your needs. 1-800-544-8436O-FLUTE BIT (SOLID CARBIDE)Thisimageshowsasolidcarbide, this tool on materials such as:PolycarbonateABSP olystyrenePVCand other flexible plastics1-800-544-8436O-FLUTE UPCUTTheO-FluteupcutbitfeaturesthesameO- Flutegeometryneededforefficientchipremov alwhenroutingplastic, ,suchas:AcrylicsNylonsPlexiglassand other rigid SPIRALT heupcutspiralbitisusedwhengettingthechip soutofthecutiscriticallyimportant,orwhen thematerialislaminatedorcoatedononesideo nly, (longerrunsshouldconsideraPCDdiamondbita sitismorecost-effective).

9 UPCUT BITA ballnosetoolisagreatchoiceforcoveandflut ingoperations, ,butaballnosebit,duetoitsroundedshape, (picturedbelow), CUT BITT hedowncutspiralbitprovidesasuperbtopsurf acefinish,butitdoesruntherisk,dependingo napplication, , , ,alwaysusetheshortestpossiblecutlengthfo rdados,groovesandrebates, ,aninsertbitwilldecreasecostconsiderably withinashortperiodoftimeifthetoolisavail ableinthediameterneeded.(Imagebelow)1-80 0-544-8436 COMPRESSION BITT hecompressionbitisdesignedtocutmaterials thathavealaminate,melamine,HPL,paint, , ,compositematerialandmelamine, !Picktherightoneforthejob!Ifusing orlargercompressionbits, bit compression bit Insert Bit for >3/4 diameter1-800-544-8436 COMPRESSION CHIP BREAKER ,whicharenotchesmachinedinanoffsetpatter nintotheflutes, , OR DOWNCUT CHIPBREAKER BITT heupordowncutchipbreakerisagreatchoicefo rcuttingcompositepanelsandplywoodwhereag oodsurfacefinishononesideisneeded.(downc utforbestfinishontop,andupcutformachinin gface-down).

10 Theinsertoptionpicturedbelow,featuresase lectionofinsertknivesthatareeitherstraig ht, OR DOWNCUT ROUGHING BITA roughingbitisdesignedtoremovealotofmater ialquickly,but,asthenameimplies, (picturedbelow)whichisavailablewitheithe rcarbideordiamond(PCD) ROUTER ,singleflute,twofluteorthreeflutedisposa ble, , TIPS TO REMEMBER Alwaysadaptthecuttinglengthoftherouterto oltothepanelthickness, Alwayschosethestrongertool, ,selectsmalldiametertoolsforpartsthatare pronetomoving. Chipclearanceisbetteronlargerdiametertoo ls,thereforewhenrunninghighfeedratesandt hickerpanels,useadiameterof5/8 orgreater. Selecthighestaccuracyclampingtools.(Heat shrink,HydroChuckorPreziso) Ifusingcolletchucks,replacecolletsregula rly.(every500machinehours!)1-800-544-843 6 FOR MDF / PARTICLEBOARDCARBIDE OR DIAMOND?ThereisnodebatethatPCD(polycryst allinediamond) ,therewasagoodargumenttostayawayfromdiam ondrouterbits,becausemostcompaniespromot ingthemonlyofferedsinglefluteondiameters of and PCDbitsthatare2-flute!