Machining Dry Is Worth A Try

39
Reducing cutting fluid use offers the chance for considerable cost savings. Tool life
may even improve.

Article: 10/1/2003
DON GRAHAM, DAVE HUDDLE AND DENNIS MCNAMARA
1.

2.

The end mill shown here offers super-positive radial and axial cutting rake angles.
High positive rake can reduce power consumption and help to discourage chip
welding.

PreviousNext
Related Suppliers
 Seco Tools, LLC
Find more information about:
 Cutting Tools
 Metalworking Fluids
 Milling Tools

At a plant we visited recently, the jump in performance that came from removing the
cutting fluid took the personnel by surprise. The discovery came by accident. A
shortage of cutting fluid forced one shift to machine part of its production quota dry.
Necessity being the mother of invention, employees experimented to determine
whether they could still produce effectively. What they discovered is that investing in
cutting fluids does not necessarily return a dividend.

The economics of using cutting fluids have changed dramatically over the past two
decades. In the early ’80s, buying, managing, and disposing of cutting fluids
accounted for less than 3 percent of the cost of most machining jobs. Today, fluids—
including their management and disposal—account for 16 percent of the cost of the
average job. Because cutting tools account for only about 4 percent of the total cost
of a machining project, accepting a slightly shorter tool life for the chance to eliminate
the cost and headaches of maintaining cutting fluids could be the less expensive
choice.

And tool life may not even go down. Because coated carbide, ceramics, cermets,
cubic boron nitride (CBN), and polycrystalline diamond (PCD) are all brittle, they are
susceptible to the chipping and breaking caused by thermal stresses—especially
those found in face-turning and milling operations—that can be aggravated by the
introduction of coolant.

In milling, for example, the cutting edges heat and cool as they enter and exit the
work. Expansion and contraction from these temperature fluctuations cause fatigue.
Eventually a series of thermal cracks resembling a comb will form perpendicular to
the edge and cause it to crumble.

Introducing a cutting fluid often makes the situation worse for a simple reason. Most
of the cooling effect goes to the parts of the work that are already cooler than the cut.
Experts debate whether any cutting fluid at all reaches the cutting zone, the zone
between the chip and the part, to control the heat of machining at its source. Fluids
tend to cool only the surrounding region—areas that were previously warm—thereby
intensifying temperature gradients and increasing thermal stresses.

Tapping, reaming and drilling typically do need the help that a cutting fluid can offer—
but not necessarily for cooling. Drilling in particular calls for lubrication at the drill’s tip
and flushing to eject chips from the hole. Without fluids, chips can bind in the hole,
and average roughness of the machined surface can be twice as high as what is
possible with a wet operation. Lubricating the point of contact between the drill’s
margin and the hole’s wall can also reduce the torque required from the machine.

Some Materials Like To Stay Dry

In addition to cost and tool life, another factor affecting the choice of dry machining is
the workpiece. Sometimes, a cutting fluid can stain the part or contaminate it.
Consider a medical implant, such as a ball joint for a hip. Fluids are undesirable
where there is the fear of contamination.

The workpiece’s suitability for a dry process also depends on the material. A cutting
fluid can be superfluous for cutting most alloys of cast iron, and carbon and alloyed
steel, for example. These materials are relatively easy to machine and conduct heat
well, allowing the chips to carry away most of the heat generated. The exception is
low-carbon steel, which becomes more adhesive as the carbon content falls. These
alloys might need a fluid as a lubricant to prevent welding.

Cutting fluids normally are not necessary when machining most aluminum alloys
because of the relatively low cutting temperatures. In situations where welding of
chips does occur with these materials, highly positive rake angles and sharp edges
that shear the material usually solve the problem. However, high pressure coolant
may be helpful when cutting aluminum alloys at high speeds where a simple air blast
is not enough to help break and evacuate chips.
Machining stainless steels dry is a little more difficult. Heat can cause problems in
these materials. It can over-temper martensitic alloys, for example. In many austentic
alloys, heat also does not flow well from the cutting zone into the chips because
thermal conductivity tends to be low. Overheating at the cutting edge therefore can
shorten tool life by an unacceptable amount. Another reason that cutting fluids are
usually necessary for cutting stainless steel is that many alloys are gummy, meaning
they have a propensity to cause build-up along the cutting edge leading to a poor
surface finish.

For a number of materials, dry machining is seldom an option. High-temperature

alloys make up an entire class of materials in need of cutting fluids. Cutting in nickel-
and chromium-based alloys in particular produces extremely high temperatures that
require a cutting fluid to dissipate the heat. The lubricity of a fluid also keeps heat
generation to a minimum.

Cutting fluids are mandatory for cutting titanium. Although researchers are studying
ways to cut titanium dry, the properties of this material pose significant obstacles for
doing so. It is gummy, has low thermal conductivity, and (in the case of some alloys)
has a low flash point. Consequently, the chips do not carry the heat away, and the
workpiece can get hot enough to ignite and burn. (Magnesium burns easily, too,
though it chips readily.) Cutting fluids prevent the problem by lubricating the edge,
flushing the chips away and cooling the workpiece. To ensure that the cutting fluid
performs these functions well, titanium alloys prefer cutting fluids delivered at high
pressure, usually in the range of 4,000 to 7,000 psi.

On occasion, powdered metals also need a cutting fluid to generate a thin coating of
oil as a rust inhibitor.

Tools Must Control Heat

While some shops have learned the value of dry machining by accident, many others
have failed to see the benefits even when they have purposefully attempted it. The
reason is that success at dry machining requires more than just eliminating coolant—
it requires a methodical approach to controlling heat in the overall process.

The most important way that the tool affects heat transfer is by creating good chips.
Chips can carry away 85 percent of the heat generated from the cutting action and
allow only 5 percent to enter the workpiece while 10 percent flows into the tool and
elsewhere. Modern chip grooves pressed into the surface of tools are a great help in
breaking chips into manageable shapes and sizes. Because the chips are hotter and
therefore more ductile than their counterparts in wet machining, they are more
difficult to break and more likely to produce dangerous chip tangles resulting in poor
surface finishes. Using a chip groove designed to shear stringy materials will help to
solve this problem. Although such edges tend to have more positive rakes, they are
not as fragile and susceptible to breakage as they would be in wet applications. The
high cutting temperatures inherent in dry machining usually soften the carbide
slightly, which increases its toughness, reducing the likelihood of chipping and
improving the reliability and longevity of the tool.
For the same reason, switching to a slightly harder tool upon going dry rarely reduces
tool life or degrades the consistency of the cut. In fact, the opposite is true. The
harder substrate ensures that the edge retains its integrity at high cutting
temperatures, yet the slight softening prevents it from being too brittle. Consequently,
users can specify a harder grade of carbide to resist both the deformation and
cratering (chemical dissolution of the tool edge) that would otherwise shorten tool life
unacceptably in dry applications.

Because the tools designed for dry machining can be sharper and tend to be freer
cutting than their counterparts for wet machining, they actually generate less friction
and help to control heat. Studies in drilling have shown that reducing the edge hone
to create a sharper drill can reduce the cutting temperature by 40 percent. Not only
do sharp edges keep the temperature low, but they also reduce runout and improve
surface finish.

Another way to assist chip breakage and evacuation from the cut is to replace a liquid
cutting fluid with a gaseous one, shop air being the most common. Although it is not
efficient at cooling, a blast of shop air is sometimes enough to blow chips from the cut
to prevent them from being re-cut and from transferring unwanted heat into the work
and machine. When lubrication is necessary, users can apply a high-efficiency
lubricant as a mist that is consumed in the cutting process. The most effective
method is a relatively new technique sometimes referred to as minimum quantity
lubrication (MQL), which injects minute amounts of coolant through the tool.

Coatings Insulate The Tool

Tool coatings also play an important role in guarding the cutting edge during dry
machining. Some of the most effective cutting tool inserts for dry machining combine
a specially engineered coating system with a cobalt-enriched zone substrate offering
a hard interior and a tough surface. An exceptionally thick, 20-micron multi-layer
coating is produced using a combination of conventional and medium-temperature
chemical vapor deposition processes. The first titanium carbonitride layer produces
the necessary adhesion to the substrate as well as edge toughness. Next, a layer of
fine-grained aluminum oxide provides the effective thermal barrier needed for dry
machining and high cutting speeds. A second sandwich layer of abrasion-resistant
titanium carbonitride helps control flank and crater wear, while the top layer of
titanium nitride provides built-up edge resistance and makes it easier to determine
the wear on the insert.

Lubricious coatings reduce heat generation by decreasing friction. Coatings such as

molybdenum disulfide and tungsten carbide-carbon have low coefficients of friction
and can lubricate the cutting action. Unfortunately, these coatings are soft and have
relatively poor tool life. To compensate for this limitation, these coatings are often
used with hard underlayers, such as titanium carbide, titanium aluminum nitride,
aluminum oxide or some combination.

Find The Best Cutting Parameters

Getting good results in dry machining requires more than specifying the correct
cutting tools. It’s also important to run them at optimum spindle speeds, feed rates
and depths of cut. If changing the groove does not control the chips adequately, for
example, try adjusting the feed rate next. Increasing the feed rate usually offers the
best results, but in rare instances, a decrease in feed rate can be beneficial.

Using the appropriate cutting parameters can also help to keep heat generation to a
minimum. The most obvious way that higher speeds and feeds can do this is to
reduce the chip load while getting through the material faster. Spending less time in
the cut reduces the time available for generating heat and for letting it soak into the
workpiece.

But sometimes lowering the spindle speed by about 15 percent is the best course of
action for reducing cutting temperatures. To prevent productivity from suffering, users
can increase the feed rate by a comparable amount. Be sure to consult the
machine’s torque chart to ensure that the lower speeds and higher feeds do not
increase the torque requirements and bog the spindle down. If the torque
requirements exceed the capacity of the spindle, choose a tool with a smaller
diameter. If the higher feed rate hurts surface finish, then increase the nose radius of
the tool to compensate.

In milling, depth of cut also influences cutting temperature because it affects both
pressure and the cooling time. Cutting inserts of fully engaged tools spend half their
time heating in the cut and the other half cooling in the air. When the step-over is 50
percent, however, they spend only a quarter of a rotation in the cut and three-
quarters of the rotation in the air. In other words, an insert spends half as much time
getting hot and much more time cooling. Most tool manufacturers determine the
depths of cut for optimal cutting temperatures for various hardness ratings, so follow
their recommendations.

Machines Play A Role, Too

As the tool ejects the chips from the cutting zone, the machine must do its part to
carry the chips away quickly. If the chips accumulate in the bed of the machine or
elsewhere for even relatively short periods, then the heat inside the chips also will be
able to flow into body of the machine, causing growth and minute distortions that can
affect the accuracy of precision work.

Without cutting fluid to flush the chips and to absorb heat, the machine must rely on
its design to remove the chips efficiently. For dry milling, horizontal-spindle machines
tend to be best because they allow the chips to fall directly onto a chip conveyor
under the machine. In fact, some builders have designed their latest HMCs to be
open in the center to eliminate horizontal surfaces that can collect chips in the work
envelope.

For turning, the preferred spindle orientation is just the opposite. Vertical chuckers
are totally enclosed so inertia throws the chips against the walls as the part spins.
The chips can then fall to a chip conveyor below. Many builders have designed their
latest vertical lathes with inverted spindles, which exploit gravity further.
Although chip conveyors are not standard features on all machines today, they are
mandatory for dry machining. A vacuum filter also can remove dust in enclosed
machines cutting cast iron and graphite.

No matter how efficient the machine is at removing the chips, it and the workpiece
are more sensitive to temperature variations when there is no cutting fluid present to
add thermal stability. Consequently, applications involving tight tolerances might
need a machine with a symmetrical design and a thermal compensation package to
adjust offsets on the fly. Users also might consider measuring critical dimensions on
the workpiece periodically with an online probe or at an off-line measurement station
to monitor thermal drifting and to take corrective action as necessary.

Another method for controlling thermal fluctuations is to plan the process to keep
these fluctuations to a minimum. For example, the operator might have to give the
machine time to reach a steady state after starting it in the morning and use
automation to keep the machine running during breaks. For applications that perform
several operations in one clamping, plan the order of operations to perform the dry
machining operations first and the drilling, tapping, and other wet operations last.
Taking this precaution keeps usage of cutting fluids to a minimum and prevents them
from interfering with the operations that are run dry.

About the authors: Don Graham, Dave Huddle and Dennis McNamara work for
cutting tool supplier Seco-Carboloy in Warren, Michigan. They are the product
managers for (respectively) turning, advanced materials and milling.

http://www.mmsonline.com/articles/machining-dry-is-worth-a-try

Key To High-Speed Aluminum Machining

Technological developments such as the Makino MAG-Series machines have made tooling
vendors rethink the core concepts of their tooling designs. To get the most out of any state-of-the-
art machine technology, it is vital to apply the right tooling and programming concepts.
The primary tooling concerns when machining aluminum are: minimizing the tendency of
aluminum to stick to the tool cutting edges; ensuring there is good chip evacuation from the
cutting edge; and ensuring the core strength of the tool is sufficient to withstand the cutting forces
without breaking.
Materials, coatings and geometry are the three elements in tool design that interrelate to minimize
these concerns. If these three elements do not work together, successful high-speed milling is not
possible. It is imperative to understand all three of these elements in order to be successful in the
high-speed machining of aluminum.
 If the elements of material, coating and geometry
do not work together, successful high-speed aluminum milling is not possible.

When machining aluminum, one of the major failure modes of cutting tools is the material being
machined adheres to the tool cutting edge. This condition rapidly degrades the cutting ability of
the tool. The built-up edge that is generated by the adhering aluminum dulls the tool so it can no
longer cut through the material. Tool material selection and tool coating selection are the two
primary techniques used by tool designers to reduce the occurrence of the built-up edge.
Two different carbide materials used in high-speed machining tools are sub-micron grain and
course grain. Sub-micron grain carbide material has generally been accepted as the preferred
material of choice because it is very hard and maintains a sharp cutting edge. When machining
aluminum at very high speeds, however, this conventional wisdom is incorrect.
The sub-micron grain carbide material requires a high cobalt concentration to achieve the fine
grain structure and the material’s strength properties. Cobalt reacts with aluminum at elevated
temperatures, which causes the aluminum to chemically bond to the exposed cobalt of the tool
material. Once the aluminum starts to adhere to the tool, it quickly forms a built-up edge on the
tool rendering it ineffective.
The secret is to find the right balance of cobalt to provide adequate material strength, while
minimizing the exposed cobalt in the tool for aluminum adherence during the cutting process.
This balance is achieved using coarse-grained carbide that provides a tool of sufficient hardness
so as to not dull quickly when machining aluminum while minimizing adherence.
The second tool design element that must be considered when trying to minimize the built-up
edge is the tool coating. Tool coating choices include TiN, TiCN, TiAIN, AlTiN, chrome nitrides,
zirconium nitrides, diamond and diamond-like coatings (DLC). With so many choices, aerospace
milling shops need to know which one works best in an aluminum high-speed machining
application.
The Physical Vapor Deposition (PVD) coating application process on TiN, TiCN, TiAIN, and
AlTiN tools makes them unsuitable for an aluminum application. The PVD coating process
creates two modes for aluminum to bond to the tool—the surface roughness and the chemical
reactivity between the aluminum and the tool coating.
The PVD process results in a surface that is rougher than the substrate material to which it is
applied. The surface “peaks and valleys” created by this process causes aluminum to rapidly
collect in the valleys on the tool. In addition, the PVD coating is chemically reactive to the
aluminum due to its metallic crystal and ionic crystal features. A TiAIN coating actually contains
aluminum, which easily bonds with a cutting surface of the same material. The surface roughness
and chemical reactivity attributes will cause the tool and work piece to stick together, thus
creating the built-up edge.
In testing performed by OSG Tap and Die, it was discovered that when machining aluminum at
very high speeds, the performance of an uncoated coarse-grained carbide tool was superior to that
of one coated with Tin, Ticn, TiAlN, or ALTiN.
This testing does not mean that all tool coatings will reduce the tool performance. The diamond
and DLC coatings result in a very smooth chemically inert surface. These coatings have been
found to significantly improve tool life when cutting aluminum materials.
The diamond coatings were found to be the best performing coatings, but there is a considerable
cost related to this type of coating. The DLC coatings provide the best cost for performance value,
adding about 20 percent to 25 percent to the total tool cost. But, this coating extends the tool life
significantly as compared to an uncoated coarse-grained carbide tool.
The rule of thumb for high-speed aluminum machining tooling designs is to maximize space for
chip evacuation. This is because aluminum is a very soft material, and the feedrate is usually
increased which creates more and bigger chips.
The Makino MAG-Series aerospace milling machines, such as the MAG4, require an additional
consideration for tool geometry—tool strength. The MAG-Series machines with their powerful
80-HP spindles will snap the tools if they are not designed with sufficient core strength.
On previous technology, the number of flutes on the tool had to be increased to provide the proper
chip load at speeds required to achieve high quality cuts in aluminum. With the 30,000-RPM and
the 80-HP spindle technology, the number of tool flutes must be reduced and the core strength of
the tool increased.
The high RPM capability of the spindle will ensure the proper chip load and the strong core tool
strength. This enables the entire 80-HP to cut metal without fear of tool breakage. In detailed
testing outlined later, it was discovered that a two-flute tool provided the best geometry for chip
evacuation and tool strength.
In general, sharp cutting edges should always be used to avoid aluminum elongation. A sharp
cutting edge will create high shearing and also high surface clearance, creating a better surface
finish and minimizing chatter or surface vibration. The issue is that it is possible to achieve a
sharper cutting edge with the fine-grained carbide material than the coarse grained material. But
due to aluminum adherence to the fine-grained material, it is not possible to maintain that edge for
very long.
The coarse grained material appears to be the best compromise. It is a strong material that can
have a reasonable cutting edge. Test results show it is able to achieve a very long tool life with
good surface finish. The maintenance of the cutting edge is improved using an oil mist coolant
through the tool. Misting gradually cools down the tools, eliminating thermal shock problems.
The helix angle is an additional tool geometry consideration. Traditionally when machining
aluminum a tool with a high helix angle has been used. A high helix angle lifts the chip away
from the part more quickly, but increases the friction and heat generated as a result of the cutting
action. A high helix angle is typically used on a tool with a higher number of flutes to quickly
evacuate the chip from the part.
When machining aluminum at very high speeds the heat created by the increased friction may
cause the chips to weld to the tool. In addition, a cutting surface with a high helix angle will chip
more rapidly than a tool with a low helix angle.
A tool design that utilizes only two flutes enables both a low helix angle and sufficient chip
evacuation area. This is the approach that has proven to be the most successful in extensive testing
performed by OSG when developing the new tooling line, the MAX AL.
OSG has extensively tested the new tooling line, MAX AL on the Makino MAG4, which was
developed and tested concurrently with the release of the MAG4. The MAX AL tool is designed
for higher spindle speeds and a higher feedrate.
OSG created a corner radius, two-flute design with a K-grade or course-grain carbide. This creates
high rigidity and a thick core without sacrificing chip capacity. And it works under the most
severe conditions.
This tool achieved impressive performance with respect to metal removal rate and tool life cutting
of a wing rib part. The wing rib has general dimensions of 2000 mm-x 500 mm x 2000 mm. A
0.750-inch diameter MAX AL tool with through-coolant mist was used at 21,500 rpm and a
feedrate of 394 inches per minute (ipm), and a .68-inch depth of cut, 90 percent of the tool
diameter.
Typically OSG’s standard tools prior to the MAX AL last up to 15 hours. The MAX AL tool
lasted nearly 90 hours during this test cut with an amazing cycle time of 2 hours and 30 minutes
per part.
Prototype Features

Through coolant mist DLC coating and special

surface treatment on flutes Bigger chip room and more rigidity

Slow helix angle and short flute

While designing the MAX AL tooling line, OSG tested 15 different one-inch diameter prototype
tools at Makino’s facility in Japan. The axial depth was 15 mm, and radial depth 20 mm on
aluminum material 7075-T651. Water-soluble coolant was used at 30,000 rpm, with a feedrate of
20,000-mm/min achieving chip removal rates of 366 cubic inches (6,000 cc). Ebara Mist Oil No.
6 (Ebara EcoMist) was used at 80 cc/h with a mist conveyance pressure of 0.6Mpa/o.3Mpa.
Since the primary test concern was the material removal rate, the measurement of success for this
test was the spindle load, and maintenance of spindle RPM, at designated metal removal rates.
Each cutting tool was run with 30,000 RPM, and spindle RPM after 500mm cutting length was
measured. The less variance of spindle speed the better.
Spindle RPM after 500 mm cut length at stated cutting conditions
Prototype Tools Material Removal Rate

4500 cc/min 5000 cc/min 5400 cc/min

TEST 1 (Helix Angle 30°) 28800 27500 25800

TEST 2 (Helix Angle 40°) 28800 27400 25700

TEST 3 (Helix Angle 45°) 27900 26500 25500

TEST 5 (Helix Angle 30°) 29100 28600 27900

TEST 6 (Helix Angle 30°) 29900 28000 27600

TEST 7 (Helix Angle 30° w/DLC) 29800 29100 28000

Prototype Tools Material Removal Rate

4500 cc/min 5000 cc/min 5400 cc/min

TEST 8 (Helix Angle 20°) 29600 28800 28000

TEST 9 (Helix Angle 25°) 29900 29500 28500

In this test it was discovered tools #7, #8 and #9 achieved the best result. The detailed test records for each of
these three tools are outlined below.
Tool #7
Tool #7, a 25mm diameter carbide tool with two-flute endmills (45° helix angle, DLC coating with through-
coolant, 140mm tool length and a 55mm overhang) revealed the following:
No. RPM Feed Rate Axial Depth Radial Depth Material Spindle RPM at the end
(min ) (mm/min)
-1
of Cut (mm) of Cut (mm) Removal Load of cutting (min -

(cc/min) )
1

1 30000 18000 10 25 4500 109.9% 29800

(65.9kW)

2 30000 20000 10 25 5000 109.9% 29100

(65.9kW)

3 30000 18000 15 20 5400 109.9% 28000

(65.9kW)

Tool #8
Tool #8, a 25mm diameter carbide tool with two-flute endmills (20° helix angle, DLC coating with through-
coolant and a 55mm overhang) revealed the following:
No. RPM Feed Rate Axial Depth Radial Depth Material Spindle RPM at the end
(min ) (mm/min)
-1
of Cut (mm) of Cut (mm) Removal Load of cutting (min -

(cc/min) )
1

1 30000 18000 10 25 4500 109.9% 29600

(65.9kW)

2 30000 20000 10 25 5000 109.9% 28800

(65.9kW)

3 30000 18000 15 20 5400 109.9% 28000

(65.9kW)

Tool #9
Tool #9, a 25mm diameter carbide tool with two-flute endmills (25° helix angle, DLC coating with through-
coolant and a 55mm overhang) revealed the following:
No. RPM Feed Rate Axial Depth Radial Depth Material Spindle RPM at the end
(min )
-1
(mm/min) of Cut (mm) of Cut (mm) Removal Load of cutting (min -

(cc/min) )
1

1 30000 18000 10 25 4500 109.9% 29900

(65.9kW)

2 30000 20000 10 25 5000 109.9% 29500

(65.9kW)

3 30000 18000 15 20 5400 109.9% 28500

(65.9kW)

Tool #9 with mist coolant proved to be the best under this cutting condition. There was no
significant difference in spindle load between DLC and non-coating tools.

Test Tool #7 Test Tool #8 Test Tool #9

Many of the tool concepts for the OSG MAX AL did not survive the rigors of the tests, and were
not included in the test data that has been presented. The MAX AL tool design was tested in a
three-flute configuration with less chip room, causing immediate breakage.
It had been thought the three-flute tool might be an appropriate solution because this configuration
works well on machines with 15,000 to 20,000 rpm spindle. In addition to the two carbide
materials, a high-speed steel, two-flute tool was tested at 30,000 rpm and 20,000 mm/min cutting
conditions. The chip removal rate of 4.8-liters/min also led to breakage.
High-speed steel materials are not strong enough to hold up under such cutting conditions. The
80-HP, 30,000-rpm spindle of the MAG 4 simply overpowered the traditional tool design
concepts.
In aluminum high-speed machining applications, use coarse-grain carbide materials for endmills,
which should be either DLC or non-coated with wide chip room and solid rigidity. When running
at 30,000 rpm and 80-HP, the core strength of the tool is critical.
The tools do not need to have excessively sharp cutting edges for high-speed aluminum
application. No margin is desired, as that also causes a breakage problem as it provides more
torque on a cutting edge. Tools with lower helix angles perform better in this application.
Most importantly, for new high-quality products like the MAG-Series and the MAG4 from
Makino, understand that the rules are being re-written. The methods traditionally employed will
not necessarily yield the best result.
No other machine tool on the market today has the ability to handle the punishment of such tests
as does Makino equipment. A key factor is that the spindles of many other machine tool
companies will fail, as they can not handle the stresses incurred when tools are broken off as done
in our testing.
Such machine tools can save a company 65 percent to 75 percent versus purchasing a gantry-type
system, and can make an operator up to four-times as efficient.
Speak to Makino’s engineers and learn what they already know about their machines as well as
tool companies like OSG. An expertise in high-speed aluminum milling and an understanding of
the three elements of tool design can make you successful in high-speed aerospace machining.
https://www.radical-departures.net/articles/understanding-the-elements/