[TheForge] Not entirely OT - just neat CNC video

[Bruce .]

Nice video.  I could have lived w/o the elevator music background, tho.

On Tue, Nov 6, 2012 at 9:58 AM, Andrew Vida <osan at netlabs.net> wrote:
> About twenty years ago I was reading an article in Mechanical
> Engineering on s a flight to a client that described a process called
> "whirling" - a machining method by which unorthodox tool paths utilizing
> high surface speeds, heavy cuts,and special tooling materials and
> geometries are used such that better than 99% of the heat generated
> remains IN THE CHIP.
>
> The result of this augmented tool path philosophy is faster machining,
> virtually no heat transmitted to the machined part, and vastly improved
> cutting tool life.  The article quoted a manufacturer of ring and pinion
> gears for automotive final drives which stated that tool life for
> cutting fully hardened gear blanks went from 13K to about 230K before
> needing to swap tools, as I recall but do not quote me on those figures.
>   The point is that tool life grows dramatically when tool paths are
> more precisely calculated for a given geometry of cut, material, heat
> treat, etc.  These precisely determined tool paths, coupled with the
> right cutting tool geometries and materials such as CBN and diamond,
> confine heat to the chip almost entirely.
>
> This is a short video by Becker, a German manufacturer of such tooling.
>   It is a demonstration of machining high-hardness materials at very
> high speeds - the threading is particularly impressive, as is the fact
> that they held tolerances of 0.95 MICRON on such materials with
> beautiful surface finishes.  They guarantee consistent 3 micron
> tolerance in materials as hard as RC60, which is quite impressive.  You
> will immediately note how most of the chips coming off the work glow
> bright yellow as they shear away.  Good fun, this.
>
> http://www.youtube.com/watch?v=bvHMVkfweCc
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-- 
Bruce
NJ