Eliminate Chatter and Solve Finish Problems
Eliminating chatter is a great way to improve surface finish when performing CNC milling. Okuma's Machining Navi M-i detects chatter and automatically adjusts spindle speed to eliminate chatter, thus improving surface finish. This is a terrific tool for the mold/die industry.
Surface finish problems can be profit killers in the moldmaking shop. One of the most common causes is chatter created by vibration in the CNC machine tool cutting process. This can lead to higher costs, delayed deliveries and even lost orders due to poor quality. In addition, vibration can cause uneven tool wear, resulting in poor surface finish, geometry inconsistencies and reduced tool life.
Chatter is caused by the inherent natural frequency of the cutting tool. It can be triggered by many process conditions: toolholding, cutter tooling, part fixturing and machine conditions. Typically operators try to combat chatter by combining multiple solutions, but some of these may impossible to implement due to part geometries or machine limitations. Fortunately, there is new technology available today that can eliminate chatter from your cutting processes.
Here are techniques commonly used to combat chatter and guidelines to establish a foundation for optimizing the moldmaking process.
Correct alignment lock selection will reduce maintenance costs, molding downtime and increase part quality over the mold’s entire life.
With moldmaking the focus is on injection molding or other mold types that use wire EDM or CNC machining centers to create the mold components. Your typical machining center weighs several tons and has a relatively small working envelope compared to a CNC router. The mill’s massive construction lends itself to machining rigid materials with very tight tolerances. While this type of CNC is suited for injection molding components, it isn’t always the ideal tool for the job when we broaden our scope of moldmaking and the current opportunities in the marketplace