Milling For Smoothness

Continuous MillingThere are a lot of forces generated during milling.When you stop so do the forces.Plus all of the teeth now cut in one spot, no longer spread out.

Importance of the Water System

Too much water presents problems:

Water costs money.

Excessive water makes the water truck driver have to go and fill up more often and it maybeYou..

Inlaying use as little water as you can.

Water usages are: dust control, toothcooling, and tooth rotation. Use only enough to accomplish these 3 things.

We have to stop to get the water.

RX-900

AM

AUTO

2D Control Systems

AUTO

AM

AUTO

V

L R

MA

RX-900

AUTO

AM

AUTO

V

L R

MA

Averaging Systems

AM

AUTO

3D Control Systems

Mill to Grade based on Position

Proper Maintenance

Proper Maintenance

Proper Holder Wear

anti-seize

Tool Wear Characteristics

At Stage 3Tool has lost 0.365 “ [9.3 mm] of

gage height

0.43 in20.15 in2 287% Increase in Surface Area

Production Tradeoff

0 2 4 6 8 10 12 140

20

40

60

80

100

120

140

160

180

RX-900 New Teeth

Milling Depth (inch)

Adva

nce

Rate

(fpm

)

0 2 4 6 8 10 12 140

20

40

60

80

100

120

140

160

180

RX-900 New Teeth

RX-900 Stage 4 Teeth Wear

Milling Depth (cm or inch)

Adva

nce

Rate

(mpm

or f

pm)

Production Tradeoff

Look at the Holders

Caliper set at EXACTLY 2”

The tooth tip should be centered on the blue line.

The red line shows the misalignment of the tooling due to the face wear on the tooth holder.

Novatec Diamond, Kenamental

•

Both fit into a Kenametal quick change holder

Both are the same height

Tooth Pattern

Keep it Clean

Your Cut surface is only as good the surface you Walked on.

If you have this to work with you willnever achieve grade.

Why?

Clean up your messOur shovel is on the water truck.

The automatics will take that out…

The Math of Milling

Drum RPM

ForwardSpeed

Line Spacing

0Lacing Pattern

Diameter

The 4 Main Factors that Affect Surface Texture1. Line Spacing2. Forward Speed3. Drum RPM4. Lacing Pattern

Line Spacing and Texture

5/8” (16mm) Triple Wrap Lacing Pattern

5/8” 5/8”

≈⅛”

5/8” (16mm) Triple Wrap Lacing Pattern

5/8” (16 mm) Triple Wrap at 30 fpm

2/10” (5mm) Triple Wrap Lacing Pattern

0.2”

≈1/16”

2/10” (5mm) Triple Wrap Lacing Pattern

2/10” (5mm) Triple Wrap Lacing Pattern

Amount of Tools

12’6” (3.5 m) Full Lane DrumLine Spacing # of Teeth Cost of Teeth

5/8” (16 mm) 268 $13403/8” (9 mm) 406 $20300.2” (5 mm) 770 $3850

Nearly 3 times more teethNearly 5 times the cost

No more quick change holders

Production Tradeoff

0 2 4 6 8 10 12 140

20

40

60

80

100

120

RX-900 12'6"

Milling Depth (inch)

Adva

nce

Rate

(fpm

)

Production Tradeoff

0 2 4 6 8 10 12 140

20

40

60

80

100

120

RX-900 12'6"

RX-900 12'6" Micro

Milling Depth (inch)

Adva

nce

Rate

(fpm

)

The Math of Milling

Drum RPM

ForwardSpeed

Line Spacing

0Lacing Pattern

Diameter

The 4 Main Factors that Affect Surface Texture1. Line Spacing2. Forward Speed3. Drum RPM4. Lacing Pattern

Forward Speed

Advance Rate = 30 fpmDrum Diameter = 46”Drum Speed = 100 rpm

Advance Rate = 30 fpm

MachineAdvance

3.6”

0.071”

30 fpm

Advance Rate = 60 fpm

MachineAdvance

7.2”

0.28”

Advance Rate = 60 fpmDrum Diameter = 46”Drum Speed = 100 rpm

60 fpm

Advance Rate = 120 fpm

MachineAdvance

14.4”

1.16”

Advance Rate = 120 fpmDrum Diameter = 46”Drum Speed = 100 rpm

120 fpm

30 fpm vs. 120 fpm

2.3 miles in a day vs. 9.1 miles in a day

The Math of Milling

Drum RPM

ForwardSpeed

Line Spacing

0Lacing Pattern

Diameter

The 4 Main Factors that Affect Surface Texture1. Line Spacing2. Forward Speed3. Drum RPM4. Lacing Pattern

Drum Speed

RX-900 Drum SpeedsEngine Speed Top Sheave Bottom Sheave Gear Ratios Diameter (in) Diameter (in) 20:1 24:1

2100rpm 16 14 120rpm 100rpm2100rpm 16 15 112rpm 93rpm2100rpm 14 15 98rpm 82rpm2100rpm 14 16 92rpm 77rpm

The Math of Milling

Drum RPM

ForwardSpeed

Line Spacing

0Lacing Pattern

Diameter

The 4 Main Factors that Affect Surface Texture1. Line Spacing2. Forward Speed3. Drum RPM4. Lacing Pattern

Drum LacingsScroll Start Comparisons

Triple Wrap Double Hit Quad Wrap

Double Hit Drums

Above

Double hit Quad wrap drum

Standard triple wrap drumBelow

Pattern Comparison

7/8” DHQW at 100 FPM5/8” Triple Wrap at 100 FPM

Production Tradeoff

0 2 4 6 8 10 12 140

20

40

60

80

100

120

RX-900 12'6"

RX-900 12'6" Micro

Milling Depth (inch)

Adva

nce

Rate

(fpm

)

Production Tradeoff

0 2 4 6 8 10 12 140

20

40

60

80

100

120

RX-900 12'6"

RX-900 12'6" Standard DHQW

RX-900 12'6" Fine DHQW

RX-900 12'6" Micro

Milling Depth (inch)

Adva

nce

Rate

(fpm

)

Thank you & Slow Down