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Transcript of 1 Bluewater Wood Alliance – September 30, 2011 Aerotech System Spiral Router Bit Selection,...
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Bluewater Wood Alliance – September 30, 2011
Aerotech System
Spiral Router Bit Selection, Operation & ServiceDean Garbett
Frank Horvath
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Bluewater Wood Alliance – September 30, 2011
Tt
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Bluewater Wood Alliance – September 30, 2011
The Aerotech System provides near or complete extraction of dust and debris while cutting.
When the Aerotech System is used in conjunction with an Aerotech Ready CNC machine; the performance is guaranteed and your plant will receive immediate increases in production throughput and operating environment benefits.
- less dust
+ much healthier
= more savings
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Bluewater Wood Alliance – September 30, 2011
Cutting Tool Improvements・ Extended tool life
・ Single pass, finished cuts
・ Lower operating temperatures
Production Improvements・ Higher production throughput
・ No or little post-cycle cleanup
Sustainable Environmental Improvements・ Dramatically improves workplace environment
・ Supports environmental management programs
・ Lowers energy usage from decreased compressed air usage
・ Reduced levels of hazardous airborne particulates
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Bluewater Wood Alliance – September 30, 2011
Spiral Router Bits
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Bluewater Wood Alliance – September 30, 2011
1/3 decrease of nesting cycle time = 24 hours per month of additional production
Increased Throughput Sample
Production Business
5 minute setup 8 hour shift
10 minute nesting cycle 5 day work week
5 minute clean up 4 weeks per month
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Bluewater Wood Alliance – September 30, 2011
• General Design
• Influence of Sharpening
• Understanding the act of cutting
• How to choose your spirals
• Explore Optimizations
• New Developments
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Bluewater Wood Alliance – September 30, 2011
General Design
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Bluewater Wood Alliance – September 30, 2011
Primary
Secondary
Third, etc…
Flute
Rake
Back Relief
Design CharacteristicsHook Angle
Clearances
Flute
Affects of sharpening
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Bluewater Wood Alliance – September 30, 2011
New Tool Geometry
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Bluewater Wood Alliance – September 30, 2011
New Tool Geometry
Notice the change in rake angle with each sharpening
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Bluewater Wood Alliance – September 30, 2011
2 Sharpening
Notice the change in rake angle with each sharpening
The min. core diameter may be Reduced with each sharpening
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Bluewater Wood Alliance – September 30, 2011
Inch Metric1 .490" 12.45 mm 3.5 mm2 .480" 12.19 mm 3.4 mm3 .470" 11.93 mm 3.2 mm4 .460" 11.68 mm 3.2 mm5 .450" 11.43 mm 3.1 mm6 .440" 11.18 mm 3.1 mm7 .430" 10.92 mm 3.0 mm8 .420" 10.60 mm 3.0 mm
Flute Depth*Diameter
Service Cycle
Replace Tool
Changing Tool DimensionsBased on a 1/2” Diameter, 2+2 Compression with Standard Cutting Features
* Flute depth is maintain if “Re-Fluting” service is provided
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Bluewater Wood Alliance – September 30, 2011
Understanding the act of cutting
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Bluewater Wood Alliance – September 30, 2011
What is Ramping?
Straight Plunge Ramping Plunge
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Bluewater Wood Alliance – September 30, 2011
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Bluewater Wood Alliance – September 30, 2011
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Bluewater Wood Alliance – September 30, 2011
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Bluewater Wood Alliance – September 30, 2011
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Bluewater Wood Alliance – September 30, 2011
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Bluewater Wood Alliance – September 30, 2011
How to choose your spirals– What level of surface finish do you require?– What is the maximum Depth of Cut, Cutting
Diameter and Material Hardness?– What is the required Surface Finish, Shape of the
Cutting Path and available Feedrate/RPM?– What type of Surface Finish is required at the
bottom of the cutting path and is it Flat?
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Bluewater Wood Alliance – September 30, 2011
Finishing Cutting Edge• Consistent smooth finish• Will produce a large chip• Will produce more heat and more cutting pressure
than modified cutting edges such as Rougher or Chipbreaker designs
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Bluewater Wood Alliance – September 30, 2011
Chipbreaker Cutting Edge• Cutting edge contains 1/16” serrations in the cutting
edge– May prevent tear-out from the core material, such as in plywood or
foam core.– Smaller chip sizes during cutting operations and after
re-cutting of chips occurs– Reduced noise level due to staggered cutting edges
• Will likely produce a cut that contains some fuzzing along the core material face.
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Bluewater Wood Alliance – September 30, 2011
Roughing Cutting Edge• Cutting edge contains “Knuckles”
– Reduced cutting pressure allowing for significantly higher feed-rates in hard materials
– Smaller chip sizes created during cutting operations– Reduced noise level due to staggered cutting edges
• Will produce a cut that is slightly uneven along the core material face
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Bluewater Wood Alliance – September 30, 2011
Standard Helix Angle, 30 degrees• Provides an aggressive cutting edge that delivers
more cutting pressure, easily severing wood fibres and brittle laminated faces.
• It is important to understand that it is not only the rake angle that produces cutting pressure but also the helix angle. Together these features determine how fibrous materials are cut.
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Bluewater Wood Alliance – September 30, 2011
Low Helix Angle, 10 degrees• Produces significantly less lateral pressure on the
cutting tool that improving rigidity, allowing for longer flute lengths when cutting hard materials and reduce tool run-out
• Lower operating noise levels• May increase cutting edge life in hard materials as a
result of the lower required cutting pressure applied to the cutting edge
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Bluewater Wood Alliance – September 30, 2011
What Helix Angle is required?– 30 Degrees– 10 Degrees– Straight
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Bluewater Wood Alliance – September 30, 2011
What type of Surface Finish is required?– Finishing– Chipbreaker– Rougher
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Bluewater Wood Alliance – September 30, 2011
Which Direction should the cutting pressure be exerted?– Upcut– Downcut– Compression
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Bluewater Wood Alliance – September 30, 2011
What is the maximum Depth of Cut, Cutting Diameter and Material Hardness?– Single diameter– Lock-Mortise– Tapered
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Bluewater Wood Alliance – September 30, 2011
What is the required Surface Finish, Shape of the Cutting Path and available Feedrate/RPM?– Single Flute– Two Flute– Three Flute
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Bluewater Wood Alliance – September 30, 2011
What type of Surface Finish is required at the bottom of the cutting path and is it Flat?– Gashed– Near Flush– Flush– Ballnose– V Point
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Bluewater Wood Alliance – September 30, 2011
Explore Optimizations
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Bluewater Wood Alliance – September 30, 2011
• Optimizing your spirals– Achieve perfect cut quality– Longest tool life– Maximize number of sharpenings
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Bluewater Wood Alliance – September 30, 2011
• Feed Rate & RPM– Material to be cut– Depth of cut
• Cutting pressure & potential run-out
– Number of cutting edges• Size of Flute
– Outside Diameter (OD) clearances• Number of sharpenings
– Prevent Heeling throughout service cycles with minimal operator input
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Bluewater Wood Alliance – September 30, 2011
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Bluewater Wood Alliance – September 30, 2011
• Oscillating or Z axis Offset– Is the vertical movement of the cutting tool– The objective is to change the point of contact and
thereby increased the number of cuts a tool can make before an unusable wear point is created
– Effective when cutting melamine, veneered or other faced materials