The combination of a precise, low frequency, horizontal machine tool, new milling cutters, and high pressure coolant is the ‘titanium triangle' required for optimal, cost-effective hard metal machining. Other considerations of course are work flow considerations and CNC toolpath creation. All aspects of the hard metal machining process must be taken into account when considering the ideal system for cutting these new part materials.

Cost vs. Profits

Stiffer machine tool materials simply cost more, so naturally the machine tool technology costs more, too -- up front. However the definition of "cost" as it relates to "profit" is worth consideration. If companies would profit by cutting deeper, faster, and with better quality, then they may be losing money by not doing so. The roughly 25 percent extra up-front cost, after scrutiny, could be miniscule by comparison to what might be lost.  Further, general purpose machines last about 20,000 hours versus the 75,000 hours that application-specific machines provide. Beware of the witchcraft and wizardry of "false economy", especially when it comes to getting what is required to produce titanium and other hard metal parts.

Difficult-to-machine workpieces, typically the newest titanium grades, Inconels, high strength stainless steel alloys, and other alloys have forced an even greater design discipline on machine builders and suppliers of cutting tools, toolholders, coolant systems, and controls. They comprise a system and are necessary for successful machining results. Seek out experts who truly understand what it takes. As the "Sorting Hat" at Hogwarts School of Witchcraft & Wizardry might say, "Do your homework."

The author can be reached in India through SAP Technical & Marketing Consultants at saptech@eth.net

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