High-speed cutting method for increased tool life

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Comparative testing of Esprit Profit Turning was completed against conventional turning methods in collaboration with Esprit machine tool partners. The baseline for the test was established using a conventional ZigZag cutting strategy, and then compared to Esprit’s Profit Turning strategy. The results were successful, indicating a 25% reduction in cycle time using Profit Turning as opposed to conventional cutting methods.

Another goal of the test cut was to evaluate tool life compared to traditional cutting strategies using Esprit Profit Turning. One part with two identical features was used in the test cut. One feature was cut with the traditional ZigZag technique and the other feature was cut with Profit Turning. During the test cut, TMAC4 (Tool Monitoring Adaptive Control) from Caron Engineering was used to monitor the horsepower of the spindle. TMAC operates on the principle that the power required to cut a part increases as the tool life decreases. With the support of TMAC, the difference in horsepower between Profit Turning and conventional ZigZag strategies was measured. For each strategy, an air cut was the start, then measuring the horsepower for each pass. That data was then averaged together to show the overall horsepower value for each groove.

Testing shows a 5% increase in horsepower between each groove using the conventional ZigZag method. When comparing the two cutting strategies, the work over eight parts using Profit Turning is 10.26%, while the work using the Conventional ZigZag method is 31.3%.
(Source: DP Technology_[M]_ETMM)

The graph displays a gradual yet consistent 5% increase in horsepower between each groove using the conventional ZigZag method. (Note: As the tool wears, the machine uses more horsepower to make the cut). This same data was collected for Profit Turning. When comparing the two cutting strategies, the work over eight parts using Profit Turning is 10.26%, while the work using the Conventional ZigZag method is 31.3%. The results shown by the graph trendlines show that, by comparison to the conventional ZigZag method, users will experience a three-times increased tool life, and tooling inserts will need to be replaced less often using Esprit’s Profit Turning.

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