High-Speed Endmilling for Die, Mold, Aerospace, Racing, and Prototype Shops

The dynamics of endmilling are not taught in machining or basic metalcutting classes; however, as speed and horsepower increase, it is common for endmills to vibrate or chatter. Machinists can typically eliminate chatter from their processes, but most often at the expense of cycle time (25%-200% lost productivity). This course teaches how to improve quality while machining parts faster by testing and understanding the tool-toolholder-spindle-machine structure. These techniques have been used by industry for more than 20 years and have become more mainstream as high-speed CNC machines have spread through the industry.

Class Details

Class Name:
High-Speed Endmilling for Die, Mold, Aerospace, Racing, and Prototype Shops
Audience:
  • Machinists
  • CAD/CAM Programmers
  • Manufacturing Engineers
  • Shop Supervisors
  • Business Owners
Duration:
2 Day Course
Language:
English

Learning Objectives

Attendees will learn how to manage and perform the latest techniques in optimizing endmills for improved productivity and quality. These 5-10 minute analysis techniques can save hours and days of tool testing by quickly steering the machinist to the optimal speeds, depth of cuts, and feeds for their system. The content builds upon basic metalcutting knowledge taught in trade school, undergraduate engineering, and machinery handbooks.

Outline At-a-Glance

Day 1:

  • Introduction
  • Experimental Vibration
    • Tap Test
    • Compare endmill structures
    • Mode Shape
  • Cutting Dynamics and Stability Diagrams
    • Review cutting mechanics
    • Self-Excited Vibration
    • Stability Diagram
  • Case Studies and Course Wrap-up

Day 2:

  • (Plan to team up with Henry Ford CC or local Machine Tool Company)
  • Introduction
  • Review endmill optimization techniques
  • Machine shop demo: testing endmills
  • Analyzing endmills: stability diagrams
  • Machine shop demo: cutting tests
  • Managing parameters in CAD/CAM

Course Wrap-up

Job Roles