Discover a new and better way. Discover a New and Better Way To
Program CNC Machines 30% Productivity Increase Guaranteed.
Slide 3
Discover a new and better way to Program CNC Machines.
www.linkedin.com/scottemillers www.TheInnovationMachine.com Scott
E. Miller Industrial Engineer
Slide 4
Discover a new and better way to Program CNC Machines. In 5
Minutes What is New? Why is it Better? How is it implemented? The
Old Way & Problems The New Way & Solutions Success Stories
Next Steps
Slide 5
Discover a new and better way to Program CNC Machines. New
Technology $4M government sponsored R&D Project $20M in
supported research Machining Dynamics Tool Vibration Cutting forces
Natural Frequencies Patented & Proven Technology 15 US &
International Patents Used by several companies
Slide 6
Discover a new and better way to Program CNC Machines. Faster
Decreased Setup Times Decreased Cycle Times Cheaper Decrease
Tooling Cost Eliminate Chatter and Tool Breakage Lower Spindle
Maintenance Costs Better Surface Finish Tighter Tolerances
Slide 7
Discover a new and better way to Program CNC Machines. Improve
CNC Milling Simple Implementation Less than 15 minutes of internal
resources per tool Works with your existing machines, tools, and
software Affordable (only $250 per tool), quick payback, high ROI
You dont pay UNTIL and UNLESS you are 100% satisfied GUARANTEED to
increase productivity by 30% Web Based Project Monitoring
Slide 8
Discover a new and better way to Program CNC Machines. CNC
Programmer The Problem: Determining the best speed, feed, depth
& width of cut What Speed? The Old Way CNC Setup Program Tool
Path Setup & Run First Part Tooling Rep Information Resources
30 Years Experience
Slide 9
Discover a new and better way to Program CNC Machines. CNC
Programmer The Problem: Determining the best speed, feed, depth
& width of cut The Old Way CNC Setup Program Tool Path Setup
& Run First Part CHATTER ! 723456 1
Slide 10
Discover a new and better way to Program CNC Machines. CNC
Programmer The Problem: Determining the best speed, feed, depth
& width of cut The Old Way CNC Setup Program Tool Path Setup
& Run First Part CHATTER ! 7 2 3456 12 Trial & Error
Slide 11
Discover a new and better way to Program CNC Machines. CNC
Programmer The Problem: Determining the best speed, feed, depth
& width of cut The Old Way CNC Setup Program Tool Path Setup
& Run First Part EXCEEDS MACHINE POWER 7 2 456 123 Trial &
Error
Slide 12
Discover a new and better way to Program CNC Machines. CNC
Programmer The Problem: Determining the best speed, feed, depth
& width of cut The Old Way CNC Setup Program Tool Path Setup
& Run First Part CHATTER ! 7 2 3 4 56 4 1234 Trial &
Error
Slide 13
Discover a new and better way to Program CNC Machines. CNC
Programmer The Problem: Determining the best speed, feed, depth
& width of cut The Old Way CNC Setup Program Tool Path Setup
& Run First Part CHATTER ! 7 2 3 45 6 4 12345 Trial &
Error
Slide 14
Discover a new and better way to Program CNC Machines. CNC
Programmer The Problem: Determining the best speed, feed, depth
& width of cut The Old Way CNC Setup Program Tool Path Setup
& Run First Part CHATTER ! 7 2 3 45 6 4 12345 6 Trial &
Error
Slide 15
Discover a new and better way to Program CNC Machines. CNC
Programmer The Problem: Determining the best speed, feed, depth
& width of cut The Old Way CNC Setup Program Tool Path Setup
& Run First Part 7 2 3 45 6 4 STABLE PREFERRED SPEED 12345 6 7
Trial & Error
Slide 16
Discover a new and better way to Program CNC Machines. The
Problem: Determining the best speed, feed, depth & width of cut
The Old Way Program Tool Path Setup & Run First Part 7 2 3 45 6
4 12345 6 7 Trial & Error Resulting Problems Excessive Setup
Time Lack of Skilled Resources (Programmers & Setup) Poor tool
life, chatter, tool breakage Poor surface finish or loss tolerances
Long cycle times due to suboptimal machine parameter
Slide 17
Discover a new and better way to Program CNC Machines. The
Problem: Determining the best speed, feed, depth & width of cut
The Old Way Program Tool Path Setup & Run First Part 7 2 3 45 6
4 12345 6 7 Setup Costs Per Trial TimeHours$/HrCost CNC
Programmer1$45 Setup / Machine1$75 MaterialQtyUnit CostCost Tools
Broken0$98$0 Parts Scrapped1$5 TOTAL$125 Total Setup Cost Cost Per
Trial$125 Number of Trials7 Total Cost$875 How much does this
cost?
Slide 18
Discover a new and better way to Program CNC Machines. The
Problem: Determining the best speed, feed, depth & width of cut
The Old Way Program Tool Path Setup & Run First Part 7 2 3 45 6
4 7 Is this really the best? Can these be improved ?
Slide 19
Discover a new and better way to Program CNC Machines. Setup
& Run First Part CNC Setup CNC Programmer Program Tool Path The
Problem: Determining the best speed, feed, depth & width of cut
Root Cause of Problem Doesnt have Machining Dynamics Information
Machining Dynamics
Slide 20
Discover a new and better way to Program CNC Machines.
Machining Dynamics What is Machining Dynamics? The branch of
physics concerned with the forces that change or produce motion of
bodies For CNC Machining the study of the resulting forces when the
tool impacts the workpiece.
Slide 21
Discover a new and better way to Program CNC Machines.
Machining Dynamics What is Machining Dynamics? Tool Path Frequency
Tool Point Frequency &
Slide 22
Discover a new and better way to Program CNC Machines. Tool
Path Frequency The number of tooth impacts in 1 second (Spindle
Speed) x (Number of Teeth) 60 Seconds Tooth Path Frequency (Hz) =
Number of Teeth Spindle Speed
Slide 23
Discover a new and better way to Program CNC Machines. 1 sec
Tool Path Frequency (75 RPM x 4 teeth) / 60 = 5 Hz
Slide 24
Discover a new and better way to Program CNC Machines. 1 sec
Tool Path Frequency (75 RPM x 4 teeth) / 60 = 5 Hz 5 impacts
Slide 25
Discover a new and better way to Program CNC Machines. 1 sec
Tool Path Frequency (135 RPM x 4 teeth) / 60 = 9 Hz
Slide 26
Discover a new and better way to Program CNC Machines. 1 sec
Tool Path Frequency (135 RPM x 4 teeth) / 60 = 9 Hz 9 impacts
Slide 27
Discover a new and better way to Program CNC Machines. 1 sec
Tool Path Frequency (255 RPM x 4 teeth) / 60 = 17 Hz
Slide 28
Discover a new and better way to Program CNC Machines. 1 sec
Tool Path Frequency (255 RPM x 4 teeth) / 60 = 17 Hz 17
impacts
Slide 29
Discover a new and better way to Program CNC Machines. 1 sec
Tool Path Frequency (75 RPM x 4 teeth) / 60 = 5 Hz (135 RPM x 4
teeth) / 60 = 9 Hz (25 RPM x 4 teeth) / 60 = 17 Hz 5 impacts 9
impacts 17 impacts
Slide 30
Discover a new and better way to Program CNC Machines..01 sec
Tool Path Frequency (7500 RPM x 4 teeth) / 60 = 500 Hz (13500 RPM x
4 teeth) / 60 = 900 Hz (25500 RPM x 4 teeth) / 60 = 1700 Hz
Slide 31
Discover a new and better way to Program CNC Machines. Tool
Point Frequency Dynamic tool movement in response to cutting
forces
Slide 32
Discover a new and better way to Program CNC Machines. Tool
Point Frequency Dynamic tool movement in response to cutting forces
Depth & Width of Cut Tool Holder # of Teeth Tool Projection
Helix Angle Runout Tool Holder Length Drawbar Force Reduced Shank
Imbalance Simultaneous Fit Damped Toolholders
Slide 33
Discover a new and better way to Program CNC Machines. Tool
Point Frequency The impact causes the tool to vibrate (Time to
deflect and return to centerline) 1 sec Tool Point Frequency (Hz) =
The tool will vibrate at its natural frequency
Slide 34
Discover a new and better way to Program CNC Machines. Tool
Point Frequency At impact, the tool deflects and returns to its
centerpoint. The tool does not fully dissipate because the next
tooth results in another vibration.
Slide 35
Discover a new and better way to Program CNC Machines. Tool
Point & Path Frequencies Problems Programmed Depth To Shallow
To Deep
Slide 36
Discover a new and better way to Program CNC Machines. Tool
Point & Path Frequencies Problems Too Deep Too Shallow Chatter
Poor Tool Life Poor Surface Finish Scrap High Power Hard on Spindle
Bad Timing Programmed Depth Bad Timing Stable Cut Increased Tool
Life Better Surface Finish Energy Efficiency Higher Speeds &
Feeds Bad Timing Good Timing Excessive Chipload
Slide 37
Discover a new and better way to Program CNC Machines. Syncing
the Tool Point & Path Frequencies Change the Tool Path
Frequency (adjust rotation of the tool) Easy Change Common in many
shops Trained ear to recognize a bad sound How do you know whether
to increase or decrease the speed? Lower the Spindle Speed
Slide 38
Discover a new and better way to Program CNC Machines. Sync the
Tool Point & Path Frequencies Change the Tool Point Frequency
(adjust deflection of the tool) Increase Depth of Cut Dangerous!
Can easily break a tool No way of knowing the effect of changes
What people chase every day Searching for a unknown, moving target
Increase in depth = Increase in tool deflection
Slide 39
Discover a new and better way to Program CNC Machines.
Machining Dynamics Chatter Zones (unsynched) Stable Zones (Tool
Path and Point Frequencies are Synched)
Slide 40
Discover a new and better way to Program CNC Machines. HSM
Region Machining Dynamics Conventional Region Low Performing Region
Where most cutters run Where most cutters run You are Here
Slide 41
Discover a new and better way to Program CNC Machines. HSM
Region You should be Here 400+% higher MRR Machining Dynamics
Conventional Region Low Performing Region You are Here
Slide 42
Discover a new and better way to Program CNC Machines. HSM
Region Machining Dynamics Conventional Region Low Performing Region
The UNKNOWN Region
Slide 43
Discover a new and better way to Program CNC Machines. Setup
& Run First Part CNC Setup CNC Programmer Program Tool Path The
Solution: Machining Dynamics Information (Stable Speeds) 99.9% of
manufacturers have no way of knowing the Stable SPEEDS of each
Cutting System. For a programmer with limited machining experience,
the first educated guess could be from a handbook or the internet.
30 Years Experience Tooling Rep Information Resources Know the
Stable Speeds (Green = Stable) (Yellow = Unstable) STABLE PREFERRED
SPEED Machining Dynamics
Slide 44
Discover a new and better way to Program CNC Machines. Setup
& Run First Part CNC Setup CNC Programmer Program Tool Path The
Solution: Machining Dynamics Information (Stable Speeds) 99.9% of
manufacturers have no way of knowing the Stable SPEEDS of each
Cutting System. For a programmer with limited machining experience,
the first educated guess could be from a handbook or the internet.
30 Years Experience Tooling Rep 7123456 Trial & Error Know the
Stable Speeds (Green = Stable) (Yellow = Unstable) Information
Resources Machining Dynamics STABLE PREFERRED SPEED
Slide 45
Discover a new and better way to Program CNC Machines. Setup
& Run First Part CNC Setup CNC Programmer Program Tool Path The
Solution: Machining Dynamics Information (Stable Speeds) 99.9% of
manufacturers have no way of knowing the Stable SPEEDS of each
Cutting System. For a programmer with limited machining experience,
the first educated guess could be from a handbook or the internet.
30 Years Experience Tooling Rep Know the Stable Speeds (Green =
Stable) (Yellow = Unstable) Information Resources Machining
Dynamics STABLE PREFERRED SPEED THE BEST Parameters!
Slide 46
Discover a new and better way to Program CNC Machines. Setup
& Run First Part CNC Setup CNC Programmer Program Tool Path The
Solution: Machining Dynamics Information (Stable Speeds) 99.9% of
manufacturers have no way of knowing the Stable SPEEDS of each
Cutting System. For a programmer with limited machining experience,
the first educated guess could be from a handbook or the internet.
Know the Stable Speeds (Green = Stable) (Yellow = Unstable)
Information Resources STABLE PREFERRED SPEED Machining
Dynamics
Slide 47
Discover a new and better way to Program CNC Machines.
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Setup & Run First Part CNC Setup CNC Programmer Program
Tool Path The Solution: Machining Dynamics Information (Stable
Speeds) 99.9% of manufacturers have no way of knowing the Stable
SPEEDS of each Cutting System. For a programmer with limited
machining experience, the first educated guess could be from a
handbook or the internet. Know the Stable Speeds (Green = Stable)
(Yellow = Unstable) STABLE PREFERRED SPEED Solution Results
Decrease in setup time Skilled resources focus on other variables
(coolant, programming strategies, etc.) Increase tool life,
eliminate chatter & tool breakage Better surface finish &
tighter tolerances Decrease in cycle time
Slide 60
Discover a new and better way to Program CNC Machines. Setup
& Run First Part CNC Setup CNC Programmer Program Tool Path The
Solution: Machining Dynamics Information (Stable Speeds) 99.9% of
manufacturers have no way of knowing the Stable SPEEDS of each
Cutting System. For a programmer with limited machining experience,
the first educated guess could be from a handbook or the internet.
Know the Stable Speeds (Green = Stable) (Yellow = Unstable)
Information Resources STABLE PREFERRED SPEED Machining
Dynamics
Slide 61
Tooling Rep Information Resources 30 Years Experience Discover
a new and better way to Program CNC Machines. Setup & Run First
Part CNC Setup CNC Programmer Program Tool Path OLD WAY vs. NEW WAY
99.9% of manufacturers have no way of knowing the Stable SPEEDS of
each Cutting System. For a programmer with limited machining
experience, the first educated guess could be from a handbook or
the internet. Know the Stable Speeds (Green = Stable) (Yellow =
Unstable) STABLE PREFERRED SPEED Machining Dynamics
Slide 62
Discover a new and better way to Program CNC Machines.
Implementation - Simple, Fast, 3 Step Process 3. You Utilize 1. We
Collect 2. We Analyze 10 min/tool 5 50 min/tool Setup & Run
Part Program Tool Path Improve CNC Milling
Slide 63
Discover a new and better way to Program CNC Machines. Decrease
Cycle Time Know crucial STABLE SPEED information Eliminate Trial
& Error End Result is optimal instead of acceptable 4.5x
Improvement after 5 min tap test Decrease Setup Time We guarantee a
30% average decrease Aerospace Manufacturer - 45% Military Depot -
85% Job Shop 30 sec/part on 30,000 parts Increase Tool Life Small
job shop saves $10k of Stainless Steel Eliminate chatter marks
Decrease Scrap Die Shop stops chatter, saves $8750/yr Compare tools
to determine best option Improve Spindle Life Improve CNC
programming labor utilization Improve CNC setup labor utilization
Reallocate experienced labor Supplement Scarce Labor Resources Big
3 Automaker 4x longer spindle Life The Benefits / Success
Stories
Slide 64
Discover a new and better way to Program CNC Machines. Cost
Savings & ROI
Slide 65
Discover a new and better way to Program CNC Machines. Cost
Savings & ROI We guarantee a 30% Productivity Increase These
figures TRIPLE !
Slide 66
Discover a new and better way to Program CNC Machines. Learn
More & Contact Us for Testing www.MachiningDynamics.com Website
Videos Literature Media Articles Cost Savings / ROI Calculations
Success Stories Call or Visit Us The Innovation Machine 30 S.
Wacker Drive Suite 2200 Chicago, IL 60606 312-238-9362
Slide 67
Discover a new and better way to Program CNC Machines. Learn
More & Contact Us for Testing www.MachiningDynamics.com Website
Next Steps TEST MY FIRST TEN CALL ME WEBCAST SIGNUP Call or Visit
Us The Innovation Machine 30 S. Wacker Drive Suite 2200 Chicago, IL
60606 312-238-9362
Slide 68
Discover a new and better way to Program CNC Machines. Summary
Simple 3 Step Implementation Collect, Analyze, Utilize GUARANTEED
to increase productivity by 30% Less than 15 minutes of internal
resources per tool Works with your existing machines, tools, and
software Affordable (only $250 per tool), quick payback, high ROI
You dont pay UNTIL and UNLESS you are 100% satisfied
Slide 69
Discover a new and better way to Program CNC Machines. Learn
More www.MachiningDynamics.com Website Videos Literature Media
Articles Cost Savings / ROI Calculations Success Stories Call or
Visit Us The Innovation Machine 30 S. Wacker Drive Suite 2200
Chicago, IL 60606 312-238-9362