1 Bluewater Wood Alliance – September 30, 2011 Aerotech System Spiral Router Bit Selection,...

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Bluewater Wood Alliance – September 30, 2011

Aerotech System

Spiral Router Bit Selection, Operation & ServiceDean Garbett

Frank Horvath

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The Aerotech System provides near or complete extraction of dust and debris while cutting.

When the Aerotech System is used in conjunction with an Aerotech Ready CNC machine; the performance is guaranteed and your plant will receive immediate increases in production throughput and operating environment benefits.

- less dust

+ much healthier

= more savings

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Cutting Tool Improvements･ Extended tool life

･ Single pass, finished cuts

･ Lower operating temperatures

Production Improvements･ Higher production throughput

･ No or little post-cycle cleanup

Sustainable Environmental Improvements･ Dramatically improves workplace environment

･ Supports environmental management programs

･ Lowers energy usage from decreased compressed air usage

･ Reduced levels of hazardous airborne particulates

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Spiral Router Bits

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1/3 decrease of nesting cycle time = 24 hours per month of additional production

Increased Throughput Sample

Production Business

5 minute setup 8 hour shift

10 minute nesting cycle 5 day work week

5 minute clean up 4 weeks per month

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• General Design

• Influence of Sharpening

• Understanding the act of cutting

• How to choose your spirals

• Explore Optimizations

• New Developments

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General Design

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Primary

Secondary

Third, etc…

Flute

Rake

Back Relief

Design CharacteristicsHook Angle

Clearances

Flute

Affects of sharpening

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New Tool Geometry

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New Tool Geometry

Notice the change in rake angle with each sharpening

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2 Sharpening

Notice the change in rake angle with each sharpening

The min. core diameter may be Reduced with each sharpening

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Inch Metric1 .490" 12.45 mm 3.5 mm2 .480" 12.19 mm 3.4 mm3 .470" 11.93 mm 3.2 mm4 .460" 11.68 mm 3.2 mm5 .450" 11.43 mm 3.1 mm6 .440" 11.18 mm 3.1 mm7 .430" 10.92 mm 3.0 mm8 .420" 10.60 mm 3.0 mm

Flute Depth*Diameter

Service Cycle

Replace Tool

Changing Tool DimensionsBased on a 1/2” Diameter, 2+2 Compression with Standard Cutting Features

* Flute depth is maintain if “Re-Fluting” service is provided

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Understanding the act of cutting

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What is Ramping?

Straight Plunge Ramping Plunge

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How to choose your spirals– What level of surface finish do you require?– What is the maximum Depth of Cut, Cutting

Diameter and Material Hardness?– What is the required Surface Finish, Shape of the

Cutting Path and available Feedrate/RPM?– What type of Surface Finish is required at the

bottom of the cutting path and is it Flat?

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Finishing Cutting Edge• Consistent smooth finish• Will produce a large chip• Will produce more heat and more cutting pressure

than modified cutting edges such as Rougher or Chipbreaker designs

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Chipbreaker Cutting Edge• Cutting edge contains 1/16” serrations in the cutting

edge– May prevent tear-out from the core material, such as in plywood or

foam core.– Smaller chip sizes during cutting operations and after

re-cutting of chips occurs– Reduced noise level due to staggered cutting edges

• Will likely produce a cut that contains some fuzzing along the core material face.

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Roughing Cutting Edge• Cutting edge contains “Knuckles”

– Reduced cutting pressure allowing for significantly higher feed-rates in hard materials

– Smaller chip sizes created during cutting operations– Reduced noise level due to staggered cutting edges

• Will produce a cut that is slightly uneven along the core material face

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Standard Helix Angle, 30 degrees• Provides an aggressive cutting edge that delivers

more cutting pressure, easily severing wood fibres and brittle laminated faces.

• It is important to understand that it is not only the rake angle that produces cutting pressure but also the helix angle. Together these features determine how fibrous materials are cut.

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Low Helix Angle, 10 degrees• Produces significantly less lateral pressure on the

cutting tool that improving rigidity, allowing for longer flute lengths when cutting hard materials and reduce tool run-out

• Lower operating noise levels• May increase cutting edge life in hard materials as a

result of the lower required cutting pressure applied to the cutting edge

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What Helix Angle is required?– 30 Degrees– 10 Degrees– Straight

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What type of Surface Finish is required?– Finishing– Chipbreaker– Rougher

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Which Direction should the cutting pressure be exerted?– Upcut– Downcut– Compression

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What is the maximum Depth of Cut, Cutting Diameter and Material Hardness?– Single diameter– Lock-Mortise– Tapered

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What is the required Surface Finish, Shape of the Cutting Path and available Feedrate/RPM?– Single Flute– Two Flute– Three Flute

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What type of Surface Finish is required at the bottom of the cutting path and is it Flat?– Gashed– Near Flush– Flush– Ballnose– V Point

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Explore Optimizations

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• Optimizing your spirals– Achieve perfect cut quality– Longest tool life– Maximize number of sharpenings

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• Feed Rate & RPM– Material to be cut– Depth of cut

• Cutting pressure & potential run-out

– Number of cutting edges• Size of Flute

– Outside Diameter (OD) clearances• Number of sharpenings

– Prevent Heeling throughout service cycles with minimal operator input

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• Oscillating or Z axis Offset– Is the vertical movement of the cutting tool– The objective is to change the point of contact and

thereby increased the number of cuts a tool can make before an unusable wear point is created

– Effective when cutting melamine, veneered or other faced materials

1 Bluewater Wood Alliance – September 30, 2011 Aerotech System Spiral Router Bit Selection,...

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