Gary Rodak, President
“We involve you.”
• We hold several one hour classroom reviews of basic machining process theory and the relationships between filtration, cutting fluid chemistry, biology, and metallurgy.
“All FIVE disciplines are related and mutually influential”
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Filtration $
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Machine
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The Costs of Manufacturing
• We stay focused and are driven to reduce your cost of manufacturing.
Sequence of events for a plant wide* process improvement program. Overview
Identify top 15 to 20 high cost tools or high volume tools General audience classroom training Identify tool and coolant system issues Investigate issues and root causes Present findings, reports and recommendations Incorporate improvements into standard operating procedures Follow up key issues and findings
or wheel material choice 7. Improper resharpening or
redressing 8. Misdirected coolant flow 9. Pump sucking air 10. Restricted coolant flow
11. Foam 12. Contamination by hydraulic
*A plant wide program has the greatest impact on costs and involves the greatest number of individuals who can affect the processes.
Following are some slides taken from the presentations.
P. Chip nests (stringy chips)
H. Poor tool life/wheel life
(These 20 influential components are investigated.)
1. Concentration control 2. Microorganisms/fungus 3. Biocide levels 4. Wrong product choice 5. Improper speeds and feeds 6. Wrong tool material choice
2. Improve the surface finish during the machining processes. A. More accurate form generation. B. Attain tighter tolerances. C. Better subsequent processes. (Better coating, assembly, etc.) D. Less residual compressive stresses in parts.
浙江省医疗器械经营企业现场检查评 ..
Machining Efficiencies, Inc. is dedicated to improving the manufacturing performance of machining and grinding operations.
We focus on improving our clients profitability by identifying specific corrective action that will reduce the process costs.
Failure Modes of inserts
1. Built Up Edge phenomenon 2. Chipping Wear 3. Flaking 4. Spalling 5. Fracture 6. Flank / Nose / Face Wear 7. Notching Wear 8. Thermal Cracking (Shock) (Fatigue) 9. Crater Wear (Diffusion Wear) 10. Deformation Wear 11. Cobalt Leaching
• Causes – Excessive loads on tool – Built Up Edge (BUE) – Intermittent contact with hard inclusions – Machine or part fixture vibration – Lack of rigidity of tool holder setup – Improper selection of insert geometry / substrate / coating – Re-circulated fines / micro particles in coolant – If coated, coating may be too thick
Chipping Wear Identification & Causes
• Identification – Ragged edge on insert – Poor (streaked) surface finish on parts – Irregular wear – Leads to catastrophic tool failure (masked cause)
fluids, way oils 13. Contamination by floor
cleaners or machine cleaners 14. Incorrect tool design/wheel application 15. Incorrect metallurgy of parts 16. Part fixturing 17. Part gauging 18. Prior part processing 19. Filter malfunction 20. Machine/spindle vibration
All of the failure modes are documented with microphotographs for future reference. There are four more failure modes associated with broaching, hobbing and other similar processes. They are not included in consideration of the document file size.
Chipping Wear Cure
• Cure – Aim coolant properly – Reduce Tramp Oil content in coolant – Use coolant with Extreme Pressure (EP) additives – Make sure the machine or fixture does not vibrate – Balance spindle – Strengthen tool holder – Select insert with high cobalt content – Decrease feed rate – De-scale surface of part – Improve filtration – positive barrier – Change coating (if used) or eliminate
Machine a better chip…….. It is the core of your business
1. Reduce the cost of manufacturing A. With greater tool life. (Lower tooling costs) B. With less tool change set ups. (Less downtime)
Identify ALL the Problem(s) with your central system
(“Poor tool life or wheel life are used as examples here.”)
A. Odor B. Rust and Stain C. Loss of filter efficiency D. Poor emulsification E. Residual films F. Dermatitis G. Foaming H. Poor tool life or wheel life I. Poor microfinish J. Poor part size control K. Paint removal L. Smoke or excessive misting M. Clinkering of chips or swarf N. Fungus O. Seals or V Belts