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For best results here, we recommend an endmill with more cutting edges or flutes, which normally means lighter step-over (ae). The other factor of the component to consider is the wall straightness and surface quality requirements. Example 2 uses the longer tool – more than doubling the MRR – and also shortens the cycle time by requiring a lower number of passes. When combining all these factors, the result is the highest yield in productivity.Ĭonsider the dynamic milling application below. With dynamic milling, the radial step-over (ae) amount often permits the use of a tool with more flutes – which also supports increases in MRR and productivity.
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The most effective way to produce this type of component with optimal productivity in mind is to choose a titanium geometry tool with a cutting edge long enough to reach the full depth of the wall (ap) – matching the required fillet/corner radius on the component using dynamic milling strategies. Let’s consider a typical titanium aircraft part, that generally requires cavity and pocketing of deep thin walls. The cutting speed vc(m/min) can, however, be increased or decreased within reason – subject to the amount of step-over (ae), machine power, work-piece clamping/rigidity, coolant-to-cutting efficiency and tool holder type. Decreasing the fz, can result in rubbing on the material – generating heat which must be avoided. Going above the recommended fz can lead to overloading the cutting edge. That said, it’s very important in the Titanium and high-temperature alloys material group to stick to the manufacturer’s recommendation on feed per tooth (fz). This not only produces improved surface finish, but also a minute edge-rounding shape specifically developed to perform in a given material group. High quality endmills apply very specific microgeometry through post-grinding techniques. This is important as, if heat can’t escape, the chips soften and melt – sticking to the cutting edges and resulting in shorter tool life. Shaping and evacuating material chips in this way dissipates heat away from the cutting zone. Then, at the correct cutting parameters, it will support heat management in cut – as the set of its helix, relief and rake angles will have been designed to cut through material with minimal amount of friction. Let’s consider each these factors in more detail, since they all affect one other.Īs a first step, it’s obvious you must choose a tool optimised for this material group. This means that managing heat generated, selecting the correct application-specific tool, along with using the best set of cutting parameters are all critical to optimising tool life and metal removal rates (MRR) – therefore creating overall efficiency.
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Titanium and high-temperature alloys are some of the most difficult materials to machine, due to their high strength and tough properties – plus they can also work-harden. Urban Studies is published in association with Urban Studies Journal Limited.Jeff Boyd discusses the multiple factors involved in optimising the machining processes of difficult-to-machine materials. The journal is also committed to developing Social Media as the means of informing debates about the contemporary urban condition.
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In addition to research articles, Urban Studies publishes peer-reviewed critical commentaries, policy reviews, book reviews besides a regular series of Special Issues. We welcome all original submissions that further our understanding of the urban condition and the rapid changes taking place in cities and regions across the globe, whether from an empirical, theoretical, or a policy perspective.
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Since its inception in 1964, the journal has remained at the forefront of intellectual and policy debates on the city, and has hosted ground-breaking contributions from across the full range of social science disciplines. Urban Studies is the leading international journal for urban scholarship.