Noise represents vibration, and various vibrations can adversely affect processing. Although vibration is unavoidable in the process, it becomes a processing challenge when the vibration reaches a level that is harmful to the health of the part and the operator.
Milling, as a discontinuous cutting process, is prone to vibration. When using a long overhanging tool for milling, the production efficiency is also reduced to reduce vibration.
Now Sandvik Coromant has introduced a new generation of vibration-damping tools/accessors designed for specific tool overhang ranges, making milling vibrations less of a problem.
Source of vibration
There are various sources of vibration generated during processing. During milling, it can be affected by many factors, such as cutting in and out of the workpiece, tool performance, unstable workpiece or part characteristics, and when using long tool overhangs. There are many ways to avoid vibrations, such as using the right milling cutter, inserts, tool path, stability measures, and a good tool holder system. If longer tool overhangs require more stringent factor control, additional measures are needed to minimize the effects of vibration and increase productivity. In the milling process, when the overhang starts at four times the tool diameter, the axial depth of cut and the amount of feed have to be kept low, thus directly affecting metal removal rate, individual part cost and longer production time.
As part of the Silent Tools range of damping tools, a new generation of vibration-damping adapters for milling has been developed. We have introduced two different lengths of vibration-damping adapters for milling operations with overhangs of 4 to 5 times the diameter of the shank and 6 to 7 times the diameter of the shank. Non-standard vibration-damping adapters cover the reach of these tool overhangs or provide higher productivity.
Damping shank
After a period of development, the damping shank has reached a new level of technology. We have combined a great deal of expertise and experience in the design and application of vibration damping technology. We have added some design and manufacturing elements to help minimize and minimize amplitude. That is to say, it is possible to more accurately determine the type of vibration in different fields, and more importantly, to effectively eliminate these vibrations as the overhang becomes longer and longer, and the flexing force and the cutting force have a negative influence on the cutting tool. During processing, the vibration cannot be completely eliminated, but it is now completely reduced to a minimum level, so that it does not affect the process and results. The use of advanced simulation methods, equipment and measurement systems, combined with an in-depth understanding of structural dynamics, is likely to counteract the adverse effects of vibration on the tool.
Smoother machining with Silent Tools
The result of this research and development work is to accurately realize the functional design and manufacture of the tool damping mechanism within a certain tool overhang range. Two new standard shanks do not affect the cutting parameters due to tool overhang (the tool overhang refers to the distance between the machine tool spindle and the cutting edge) and can be used for two different overhang ranges. The amplitude is minimized.
All standardization means a compromise between the vibration reduction performance and the cutting efficiency in the machining range, but the latest vibration damping tool can improve the vibration control level without guaranteeing the loss of efficiency, and can handle different types of vibration. In addition, the new adapter allows for the use of internal cooling, which is very advantageous for certain processes and materials.
Risk of excessive vibration
To eliminate the risk of excessive vibration during milling, always pay attention to the clamping from the cutting edge to the machine itself. Stability can often be improved by increasing the robustness of the overall clamping and using a vibration damping tool. Silent Tools damping tools and the most rugged, stable, modular toolholder systems such as the ISO-compliant Coromant Capto interface are available. The natural vibration frequency of the machine tool is another important factor in the elimination of vibration, which can increase the stability according to the different structure of a single machine tool.
A new generation of vibration-damping adapters for milling has been supplied as part of the Silent Tools range of vibration-damping tools.
There are currently two different lengths of vibration-damping adapters, which are dedicated to milling operations with overhangs of 4 to 5 times the diameter of the shank and 6 to 7 times the diameter of the shank.
Silent Tools vibration-damping adapters not only solve vibration problems in machining, but are also production efficiency “multipliers”. They offer new machining possibilities for cavity machining and part features that exceed the machining range, for example in large diameter milling cutters with thin posts. The potential of new products can extend overhangs or increase productivity while extending tool overhangs. The damping adapter covers the most common areas of milling for long tool overhangs. The new system can directly improve production efficiency and greatly reduce the return on investment of the adapter.
