Reducing Cycle Time Using Dynamic Milling
Matt Deboer on 2021-12-09
The manufacturing industry has experienced great advancements in machine tool, CAD/CAM, and cutting tool technology. As technology moves forward, so do machining strategies. One such machining strategy that has become increasingly popular is Dynamic Milling. Dynamic Milling is a High Speed Machining strategy where a light radial depth of cut(RDOC) and large axial depth of cut(ADOC) combined with a constant chip thickness allows for incredibly high feed rates. When used in the correct application this can increase tool life, drastically reduce cycle time and increase Metal Removal Rate(MRR) when compared to traditional milling tool paths. In an increasingly competitive market where faster machining time at a lower cost is a must, modern machining techniques can make all of the difference for profitability.
In Dynamic Milling, chip thinning is what allows for such high feed rates. As the RDOC decreases, so does the thickness of the chip. In order to maintain the desired chip thickness of your programmed speeds & feeds, the feed per tool has to be increased accordingly. Basically, as the RDOC decreases, the feed rate must increase. This allows for the incredibly fast feed rates and high MRR.
Tool life is increased compared to traditional roughing because a light RDOC and large ADOC spreads the cutting action over a larger area and provides better heat evacuation in the chip. This leads to less heat buildup at the cutting edge and can dramatically increase tool life since high heat can be detrimental to carbide cutting tool life.
End mills with higher flute counts are generally recommended for High Speed Machining strategies. Since long flute lengths are common and the entire flute length is typically used, the larger core in high flute count end mills will provide greater strength to reduce deflection. Additional flutes also increase feed rate which is ideal for Dynamic Milling.
The limiting factor is having the correct part geometry to properly implement this strategy. When profiling, pocketing or machining wide slots where Dynamic Milling is appropriate, it is an excellent option to cut cycle time, increase tool life and MRR.