Using a Button Cutter to High Feed Ramp a Mold Core, then Plunge Finishing for Shortest Cycle Time
Summary
TLDRThis video from Des Prés Tech Center explores different milling techniques for roughing and finishing core shapes in machining. It compares high feed ramping with a button cutter versus a high feed cutter, highlighting productivity and surface quality. The video also demonstrates three finishing methods: waterline profile milling with a bull nose cutter, the same with a ball nose cutter for faster cycle times, and plunge finishing with a bull nose for accessing tight corners and reduced tool pressure. The discussion covers the pros and cons of each method, providing insights for choosing the right tool and technique.
Takeaways
- 🛠️ The video discusses two machining approaches: roughing and finishing, using different types of cutters.
- ⏱️ Roughing with a button cutter is compared to high feed cutters, showing productivity and practical considerations.
- 🔩 Button cutters leave smaller scallops on sloped surfaces compared to high feed cutters, which is beneficial for semi-finishing and finishing.
- 💰 Economically, button cutters with double sides provide 12 usable indexes per insert, making them a strong option over high feed cutters.
- 📉 The roughing process with a button cutter took 8 minutes and 47 seconds, which is longer than high feed but results in a smoother surface.
- 🛠️ Three different finishing approaches are demonstrated: bull nose cutter with water line profile milling, ball nose cutter, and bull nose cutter with plunge finishing.
- ⏲️ Using a ball nose cutter significantly reduced the cycle time to 43 minutes and 30 seconds compared to the bull nose cutter.
- 🔍 The ball nose cutter provides a good finish but may require a secondary tool for smaller radii in corners.
- 🔩 The bull nose cutter in plunge finishing approach reduced cycle time by 75% compared to the profile milling approach.
- 🏁 The video concludes by summarizing the advantages of button cutters for roughing and bull nose cutters for finishing tapered walls over ball nose or barrel type cutters.
Q & A
What are the two main machining approaches discussed in the script?
-The two main machining approaches discussed are roughing and finishing.
What type of cutter is suggested as an alternative to high feed cutters for roughing?
-A button cutter is suggested as an alternative to high feed cutters for roughing.
How does the button cutter compare to a high feed cutter in terms of productivity?
-The button cutter provides a smoother surface with smaller scallops and has more usable cutting edges, which can be more economical and efficient for certain applications.
What are the three different finishing approaches demonstrated in the script?
-The three different finishing approaches demonstrated are using a bull nose cutter with a water line profile milling approach, using a ball nose cutter, and using a bull nose cutter with a plunge finishing approach.
Why might a bull nose cutter be preferred over a ball nose cutter for finishing?
-A bull nose cutter allows for better access to tight corners and intersections, and it generates less tool pressure, which can result in fewer issues with tool deflection and the need for recutting.
What is the cycle time for roughing with a button cutter as mentioned in the script?
-The cycle time for roughing with a button cutter is 8 minutes and 47 seconds.
What is the advantage of using a ball nose cutter over a bull nose cutter in terms of cycle time?
-The ball nose cutter significantly reduces the cycle time compared to a bull nose cutter, as demonstrated by the 43 minutes and 30 seconds cycle time versus the longer time taken by the bull nose cutter.
What is the potential downside of using a ball nose cutter for finishing?
-The potential downside of using a ball nose cutter is that it may not be able to access tight corners as effectively as a bull nose cutter, requiring a secondary tool to finish those areas.
How does the plunge finishing approach with a bull nose cutter compare to the water line profile milling approach in terms of cycle time?
-The plunge finishing approach with a bull nose cutter is about four times faster than the water line profile milling approach, reducing the cycle time by 75%.
What are the economic considerations when choosing between a button cutter and a high feed cutter?
-Economic considerations include the number of usable cutting edges, the depth of cut the tool can take, and the smoother surface left by the button cutter, which may require less finishing work.
Outlines
🛠️ Machining Techniques Comparison
The script introduces a comparison between two machining approaches: roughing using a button cutter versus a high feed cutter, and finishing using bull nose, ball nose, and plunge finishing techniques. The roughing process with a button cutter is highlighted for its productivity and practical advantages over a high feed cutter, such as smoother surfaces and more usable cutting edges. The finishing section discusses the steep taper core shape and the use of different cutters to achieve various cycle times and finishes. The bull nose cutter is used for water line profile milling, the ball nose cutter for its cycle time benefits, and the bull nose cutter again for plunge finishing, which offers less tool pressure and the ability to reach tight corners.
🔩 Detailed Finishing Process and Outcomes
This paragraph delves into the finishing process using a bull nose end mill, detailing the parameters like surface feed and feed rate. It emphasizes the excellent surface finish that requires minimal polishing and the associated risks of tool wear over extended cutting times. The comparison then shifts to using a ball nose cutter, which significantly reduces cycle time while maintaining a high-quality finish. However, it lacks the ability to reach tight corners, necessitating a secondary tool for those areas. The paragraph concludes with a plunge finishing approach using the bull nose cutter, which, despite being slightly slower than the ball nose, offers advantages in tool pressure management and accessibility to tight corners.
⏱️ Cycle Time and Tool Pressure Analysis
The final paragraph summarizes the comparative advantages of different finishing techniques. It points out that the plunge finishing approach with a bull nose cutter reduces cycle time by 75% compared to the profiling method and is four times faster than the initial bull nose profile finishing. The bull nose cutter's smaller corner radius allows for better access to tight corners and intersections, and its design results in less tool pressure and deflection, reducing the need for recutting. This is contrasted with the ball nose and barrel type cutters, which have larger radii, leading to more tool pressure and the potential for oversized cuts. The paragraph wraps up by reinforcing the benefits of using a bull nose cutter for finishing tapered walls due to its low tool pressure and ability to reach tight corners.
Mindmap
Keywords
💡Roughing
💡Finishing
💡Button Cutter
💡High Feed Cutter
💡Bull Nose Cutter
💡Ball Nose Cutter
💡Water Line Profile Milling
💡Plunge Finishing
💡Cycle Time
💡Tool Pressure
💡Scalloping
Highlights
Introduction of two application examples: roughing and finishing.
Comparison of high feed ramping using a button cutter versus a high feed cutter.
Practical reasons for considering a button tool over a high feed cutter.
Three different finishing approaches demonstrated: bull nosed cutter, ball nose tool, and plunge finishing.
Description of the core shape's steep taper and the finishing process.
Roughing with a double-sided button cutter took 8 minutes and 47 seconds.
Advantages of button cutter over high feed in terms of scalp size and number of usable edges.
Economic argument for using button cutters for high feed ramping.
Finishing operation with a bull nosed cutter, resulting in a beautiful finish.
Cycle time and surface feed rates for bull nosed cutter finishing.
Risk of edge breakdown with longer tool run times.
Comparison of cycle times between bull nosed and ball nose cutters.
Advantages of ball nose cutter in terms of cycle time and finish quality.
Limitations of ball nose cutters for smaller radius corners.
Plunge finishing approach with a bull nose cutter, reducing cycle time by 75%.
Advantages of bull nose cutters for accessing tight corners and reduced tool pressure.
Conclusion on the benefits of button cutters for roughing and bull nose cutters for finishing tapered walls.
Call to action for more information on applications from de pro.
Transcripts
[Music]
hey folks coming to you again from des
prés Tech Center in the Midwest
we've got a couple of application
examples for you today
one is roughing and the other is
finishing the roughing approach is going
to be high feed ramping but using a
button cutter instead of a high feed
cutter we'll show you how that compares
in terms of productivity and also maybe
some practical reasons you might want to
consider a button tool over a high feed
once we've roughed the part then we'll
finish using three different approaches
you can see we've got a pretty steep
taper core shape here and we're going to
finish this first with a bull nosed
cutter just like this one using the
typical water line profile milling
approach after that we'll put a ball
nose tool in same diameter same speeds
and feeds and the same tool path so that
you can compare cycle times with that
finally we'll use the same bull nose
cutter that we started with but instead
of the water line finishing approach
will use plunge finishing will compare
cycle times finishes and talk about some
different pros and cons between the bull
nose and the ball no style tool and in
fact this even applies towards the
barrel type cutters that are trending
right now as well so let's go
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so I roughing is complete we have a
total depth of about three and a quarter
inches top to bottom for our core
there's a fair amount of slope on this
shape as you can see our button cutter
double-sided button cutter took 8
minutes and 47 seconds to complete the
roughing routine keep in mind with a
button tool versus high feed the scalps
that are left on the sloped surfaces are
actually smaller with a button cutter so
you do get a little bit of a smoother
surface to work with for your semi
finishing and your finishing work after
the roughing is done we ran this at
about 230 inches per minute and got that
cycle time of a little over eight and a
half minutes had we used high feed we
probably would have been upwards of 300
inches a minute and probably finished
this and maybe six or seven minutes
however we would have had a little bit
more scalloping on the sides
additionally a high feed cutter might
have given you four usable edges or six
usable edges depending on what you're
using this button cutter with double
sides actually provides 12 usable
indexes per insert so economically
speaking you could make a very strong
argument for using this type of tool for
your high feed ramping versus an actual
high feed cutter so now that we've got
the part roughed out we'll move on to
the finishing operation with the bull
nosed cutter
so four hours and ten minutes later we
have our core walls and coroner's
finished the finish is beautiful
again this was with a three-quarter inch
bull nose end mill two fluted we ran 900
surface feed and 10,000 feet per tooth
so our feed rate was around 90 inches a
minute as we went around the profile we
did program a 1/10 scalloped height so
this surface finish will require very
little to no polishing time once it
comes off the machine so in that regard
it's very good you might say well so
what if it was 4 hours I'll just run it
overnight and that's true however the
longer that tool runs on the part the
more chance there is of a little bit of
edge breakdown on our insert so there's
some risk involved in possibly losing
size the longer we're in that type of a
cut so nice finish good outcome in terms
of appearance but for our cycle time is
longer than I think most shops would
want to see for a core of this size
which is about 6 and a quarter inches
long by 4 and a quarter inches wide at
the base and it's about three and a
quarter inches tall so let's try a ball
nose cutter next and see how that
compares in terms of surface finish and
cycle time
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okay so using a 3/4 inch ball nose our
cycle time is is reduced dramatically to
43 minutes and 30 seconds so the the
larger radius on our ball nose cutter
allowed us a larger step down between
passes still gives us an extremely good
finish possibly even a little bit better
then the profiling cuts did with the
bull nose tool and the smaller radius on
that one so big improvement in cycle
time nice finish the trade-off here is
we're going to lose our ability with
that large radius on the ball nose we
can't get down tight into a corner so if
the if the workpiece calls for a smaller
radius in the corner then you're forced
to follow up the ball nose with some
type of smaller diameter or smaller
corner radius finishing tool to take in
and blend that corner to the sloped
walls so the next thing we'll take a
look at is the the bull nose cutter same
one as before but in a plunge finishing
approach versus the profile finishing
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so 48 minutes later the bullnose cutter
has finished our core surfaces using the
plunge finishing approach that's about
half four minutes slower actually then
the ball nose cutter was but about four
times faster than this same style tool
was in using a profile mailing approach
so the plunge finishing approach
literally cut the cycle time by 75% two
distinct advantages that this cutter has
over the ball nose that was a few
minutes faster number one using this
small corner radius on a bull nose
cutter allows us to get down into tight
corners intersections between a floor
and a surface wall it definitely lets us
have more access to corners than what
the ball nose tool would obviously the
ball nose cutter would require some type
of secondary tool to get in and finish
that corner intersection the second
advantage is in regards to size and tool
pressure a ball nose cutter or for that
matter the new barrel type cutters both
of those type tools have a larger radius
and that means more contact more surface
area in contact with the work piece a
more surface area in contact means more
tool pressure and deflection and the
potential for having to actually recut
apart due to the fact that it comes in
oversized after the first finish pass
using a bull nose or backdraft style
tool like this the only tool pressure we
have is just on the slight corner radius
and small wiper area that does the bulk
of the work the insert then back tapers
away creating a very small amount of
tool pressure when you're cutting like
this and that generally means that we
take the part to size in one pass rather
than having to recut so to pretty
distinct advantages using this style
cutter for finishing tapered walls over
a ball nose or
over a barrel type cutter so that wraps
it up on the roughing side we showed you
how to do high feed profile ramping but
using a button cutter instead of high
feed some pretty good arguments for
using the button cutter strong robust
cutting edge it can take a good depth of
cut
you've got likely more usable cutting
edges versus high feed and you get
smaller scallops on that surface due to
the round cutting edge versus the high
feed cutting edge so that means your
semi finishing tool has a little bit
more even stock removal in store for it
so good arguments can be made for a
button cutter versus high feed on your
ramping you got to decide which works
better for your application on the
finishing side we showed you a typical
water line profile finishing using both
the bull nose and a ball nose cutter
obviously the ball nose cutter has a
huge advantage in terms of cycle time
but tool pressure is increased now
whether that's a ball nose or a barrel
type cutter definitely much more tool
pressure than using a bull know style
tool when we went to the bull nose
plunge finishing style cycle time was
very comparable to the ball nose and
we're generating a lot less tool
pressure versus a ball nose or a barrel
type cutter and we can get into these
tighter corners that we can't get into
with the ball nose so good good
advantages there in the plunge finishing
but using a bull nose low pressure tool
hopefully you found this helpful if
you'd like any more information about
this or other applications from de pro
call us at
you
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