航空宇宙部品表面粗さ要件。加工パラメータの即座のRadial Engagement (%), Max Step-over (mm)を取得。
悪い数値のコストは？典型的なジョブショップシナリオで計算してみましょう。もし 段付き加工 が15%攻撃的すぎる場合、 Widia エンドミルを余分に買うだけでなく — 予期しないダウンタイム、手直し、納期遅れのコストを払っています。
| Premature TaeguTec tool failures | $6,400/yr |
| Unplanned machine downtime | $12,200/yr |
| Rework / scrap parts | $8,700/yr |
| Excess BIG Kaiser holder wear | $2,100/yr |
| Total Annual Loss | $29,400/yr |
シナリオを逆にしてみましょう。段付き加工を最適化 — メーカー推奨の開始パラメータを特定のWidiaまたはTaeguTec工具に使用し、Hexagonプリセッターで検証 — することで年間約3万ドルを回収できます。これは新しいStarrag工具プローブまたは1年分のWidiaインサートに相当します。
ROIは即時。最初のパーツが最適化され、最初の節約日。
Radial engagement (step-over) determines how much of the tool diameter is engaged in the cut. Excessive radial engagement overloads the tool and causes vibration, while too little engagement causes rubbing and poor productivity.
40-70% for most steels with carbide end mills. Below 40% is inefficient (too many passes). Above 80% approaches slotting conditions and should use reduced feed. Aluminium can tolerate 60-80% at high feed rates.
Step-over is the primary determinant of cusp height in 3D surface machining. For ball mills: cusp height = step-over² / (8 × tool radius). Halving the step-over reduces cusp height by 75%. For flat end mills, step-over has minimal effect on floor finish.
Scallop (cusp) height is the ridge left between adjacent tool passes. It is determined by step-over and tool nose radius. CAM software typically lets you specify maximum scallop height; it then calculates the required step-over automatically.
Enter your tool diameter and radial width of cut (step-over). The calculator shows the engagement percentage and the recommended maximum step-over. For roughing, keep engagement at 40-70%; for finishing, use much smaller step-overs.
Continue with closely related tools from the machining calculator library.