Discover a new and better way. Discover a New and Better Way To Program CNC Machines 30% Productivity Increase – Guaranteed.

Discover a new and better way to Program CNC Machines. Scott E. Miller Industrial Engineer

Discover a new and better way to Program CNC Machines. In 5 Minutes… What is New? Why is it Better? How is it implemented? The “Old Way” & Problems The “New Way” & Solutions Success Stories Next Steps

Discover a new and better way to Program CNC Machines. New Technology $4M government sponsored R&D Project $20M in supported research Machining Dynamics Tool Vibration Cutting forces Natural Frequencies Patented & Proven Technology 15 US & International Patents Used by several companies

Discover a new and better way to Program CNC Machines. Faster Decreased Setup Times Decreased Cycle Times Cheaper Decrease Tooling Cost Eliminate Chatter and Tool Breakage Lower Spindle Maintenance Costs Better Surface Finish Tighter Tolerances

Discover a new and better way to Program CNC Machines. Improve CNC Milling Simple Implementation Less than 15 minutes of internal resources per tool Works with your existing machines, tools, and software Affordable (only $250 per tool), quick payback, high ROI You don’t pay UNTIL and UNLESS you are 100% satisfied GUARANTEED to increase productivity by 30% Web Based Project Monitoring

Discover a new and better way to Program CNC Machines. CNC Programmer The Problem: Determining the best speed, feed, depth & width of cut What Speed? The “Old Way” CNC Setup Program Tool Path Setup & Run First Part Tooling Rep Information Resources 30 Years Experience

Discover a new and better way to Program CNC Machines. CNC Programmer The Problem: Determining the best speed, feed, depth & width of cut The “Old Way” CNC Setup Program Tool Path Setup & Run First Part CHATTER !

Discover a new and better way to Program CNC Machines. CNC Programmer The Problem: Determining the best speed, feed, depth & width of cut The “Old Way” CNC Setup Program Tool Path Setup & Run First Part CHATTER ! Trial & Error

Discover a new and better way to Program CNC Machines. CNC Programmer The Problem: Determining the best speed, feed, depth & width of cut The “Old Way” CNC Setup Program Tool Path Setup & Run First Part EXCEEDS MACHINE POWER Trial & Error

Discover a new and better way to Program CNC Machines. CNC Programmer The Problem: Determining the best speed, feed, depth & width of cut The “Old Way” CNC Setup Program Tool Path Setup & Run First Part CHATTER ! Trial & Error

Discover a new and better way to Program CNC Machines. CNC Programmer The Problem: Determining the best speed, feed, depth & width of cut The “Old Way” CNC Setup Program Tool Path Setup & Run First Part CHATTER ! Trial & Error

Discover a new and better way to Program CNC Machines. CNC Programmer The Problem: Determining the best speed, feed, depth & width of cut The “Old Way” CNC Setup Program Tool Path Setup & Run First Part CHATTER ! Trial & Error

Discover a new and better way to Program CNC Machines. CNC Programmer The Problem: Determining the best speed, feed, depth & width of cut The “Old Way” CNC Setup Program Tool Path Setup & Run First Part STABLE PREFERRED SPEED Trial & Error

Discover a new and better way to Program CNC Machines. The Problem: Determining the best speed, feed, depth & width of cut The “Old Way” Program Tool Path Setup & Run First Part Trial & Error Resulting Problems Excessive Setup Time Lack of Skilled Resources (Programmers & Setup) Poor tool life, chatter, tool breakage Poor surface finish or loss tolerances Long cycle times due to suboptimal machine parameter

Discover a new and better way to Program CNC Machines. The Problem: Determining the best speed, feed, depth & width of cut The “Old Way” Program Tool Path Setup & Run First Part Setup Costs Per Trial TimeHours$/HrCost CNC Programmer1$45 Setup / Machine1$75 MaterialQtyUnit CostCost Tools Broken0$98$0 Parts Scrapped1$5 TOTAL$125 Total Setup Cost Cost Per Trial$125 Number of Trials7 Total Cost$875 How much does this cost?

Discover a new and better way to Program CNC Machines. The Problem: Determining the best speed, feed, depth & width of cut The “Old Way” Program Tool Path Setup & Run First Part Is this really the best? Can these be improved ?

Discover a new and better way to Program CNC Machines. Setup & Run First Part CNC Setup CNC Programmer Program Tool Path The Problem: Determining the best speed, feed, depth & width of cut Root Cause of Problem Doesn’t have Machining Dynamics Information Machining Dynamics

Discover a new and better way to Program CNC Machines. Machining Dynamics What is Machining Dynamics? “The branch of physics concerned with the forces that change or produce motion of bodies” For CNC Machining – the study of the resulting forces when the tool impacts the workpiece.

Discover a new and better way to Program CNC Machines. Machining Dynamics What is Machining Dynamics? Tool Path Frequency Tool Point Frequency &

Discover a new and better way to Program CNC Machines. Tool Path Frequency The number of tooth impacts in 1 second (Spindle Speed) x (Number of Teeth) 60 Seconds Tooth Path Frequency (Hz) = Number of Teeth Spindle Speed

Discover a new and better way to Program CNC Machines. 1 sec Tool Path Frequency (75 RPM x 4 teeth) / 60 = 5 Hz

Discover a new and better way to Program CNC Machines. 1 sec Tool Path Frequency (75 RPM x 4 teeth) / 60 = 5 Hz 5 impacts

Discover a new and better way to Program CNC Machines. 1 sec Tool Path Frequency (135 RPM x 4 teeth) / 60 = 9 Hz

Discover a new and better way to Program CNC Machines. 1 sec Tool Path Frequency (135 RPM x 4 teeth) / 60 = 9 Hz 9 impacts

Discover a new and better way to Program CNC Machines. 1 sec Tool Path Frequency (255 RPM x 4 teeth) / 60 = 17 Hz

Discover a new and better way to Program CNC Machines. 1 sec Tool Path Frequency (255 RPM x 4 teeth) / 60 = 17 Hz 17 impacts

Discover a new and better way to Program CNC Machines. 1 sec Tool Path Frequency (75 RPM x 4 teeth) / 60 = 5 Hz (135 RPM x 4 teeth) / 60 = 9 Hz (25 RPM x 4 teeth) / 60 = 17 Hz 5 impacts 9 impacts 17 impacts

Discover a new and better way to Program CNC Machines..01 sec Tool Path Frequency (7500 RPM x 4 teeth) / 60 = 500 Hz (13500 RPM x 4 teeth) / 60 = 900 Hz (25500 RPM x 4 teeth) / 60 = 1700 Hz

Discover a new and better way to Program CNC Machines. Tool Point Frequency Dynamic tool movement in response to cutting forces

Discover a new and better way to Program CNC Machines. Tool Point Frequency Dynamic tool movement in response to cutting forces Depth & Width of Cut Tool Holder # of Teeth Tool Projection Helix Angle Runout Tool Holder Length Drawbar Force Reduced Shank Imbalance Simultaneous Fit Damped Toolholders

Discover a new and better way to Program CNC Machines. Tool Point Frequency The impact causes the tool to vibrate (Time to deflect and return to centerline) 1 sec Tool Point Frequency (Hz) = The tool will vibrate at its natural frequency

Discover a new and better way to Program CNC Machines. Tool Point Frequency At impact, the tool deflects and returns to its centerpoint. The tool does not fully dissipate because the next tooth results in another vibration.

Discover a new and better way to Program CNC Machines. Tool Point & Path Frequencies Problems Programmed Depth To Shallow To Deep

Discover a new and better way to Program CNC Machines. Tool Point & Path Frequencies Problems Too Deep Too Shallow Chatter Poor Tool Life Poor Surface Finish Scrap High Power Hard on Spindle Bad Timing Programmed Depth Bad Timing Stable Cut Increased Tool Life Better Surface Finish Energy Efficiency Higher Speeds & Feeds Bad Timing Good Timing Excessive Chipload

Discover a new and better way to Program CNC Machines. Syncing the Tool Point & Path Frequencies Change the Tool Path Frequency (adjust rotation of the tool) Easy Change Common in many shops Trained “ear’ to recognize a ‘bad sound’ How do you know whether to increase or decrease the speed? Lower the Spindle Speed

Discover a new and better way to Program CNC Machines. Sync the Tool Point & Path Frequencies Change the Tool Point Frequency (adjust deflection of the tool) Increase Depth of Cut Dangerous! Can easily break a tool No way of knowing the effect of changes What people “chase” every day Searching for a unknown, moving target Increase in depth = Increase in tool deflection

Discover a new and better way to Program CNC Machines. Machining Dynamics Chatter Zones (unsynched) Stable Zones (Tool Path and Point Frequencies are Synched)

Discover a new and better way to Program CNC Machines. HSM Region Machining Dynamics Conventional Region Low Performing Region Where most cutters run Where most cutters run You are Here

Discover a new and better way to Program CNC Machines. HSM Region You should be Here 400+% higher MRR Machining Dynamics Conventional Region Low Performing Region You are Here

Discover a new and better way to Program CNC Machines. HSM Region Machining Dynamics Conventional Region Low Performing Region The UNKNOWN Region

Discover a new and better way to Program CNC Machines. Setup & Run First Part CNC Setup CNC Programmer Program Tool Path The Solution: Machining Dynamics Information (Stable Speeds) 99.9% of manufacturers have no way of knowing the Stable SPEEDS of each “Cutting System”. For a programmer with limited machining experience, the first ‘educated guess’ could be from a handbook or the internet. 30 Years Experience Tooling Rep Information Resources Know the Stable Speeds (Green = Stable) (Yellow = Unstable) STABLE PREFERRED SPEED Machining Dynamics

Discover a new and better way to Program CNC Machines. Setup & Run First Part CNC Setup CNC Programmer Program Tool Path The Solution: Machining Dynamics Information (Stable Speeds) 99.9% of manufacturers have no way of knowing the Stable SPEEDS of each “Cutting System”. For a programmer with limited machining experience, the first ‘educated guess’ could be from a handbook or the internet. 30 Years Experience Tooling Rep Trial & Error Know the Stable Speeds (Green = Stable) (Yellow = Unstable) Information Resources Machining Dynamics STABLE PREFERRED SPEED

Discover a new and better way to Program CNC Machines. Setup & Run First Part CNC Setup CNC Programmer Program Tool Path The Solution: Machining Dynamics Information (Stable Speeds) 99.9% of manufacturers have no way of knowing the Stable SPEEDS of each “Cutting System”. For a programmer with limited machining experience, the first ‘educated guess’ could be from a handbook or the internet. 30 Years Experience Tooling Rep Know the Stable Speeds (Green = Stable) (Yellow = Unstable) Information Resources Machining Dynamics STABLE PREFERRED SPEED THE BEST Parameters!

Discover a new and better way to Program CNC Machines. Setup & Run First Part CNC Setup CNC Programmer Program Tool Path The Solution: Machining Dynamics Information (Stable Speeds) 99.9% of manufacturers have no way of knowing the Stable SPEEDS of each “Cutting System”. For a programmer with limited machining experience, the first ‘educated guess’ could be from a handbook or the internet. Know the Stable Speeds (Green = Stable) (Yellow = Unstable) Information Resources STABLE PREFERRED SPEED Machining Dynamics

Discover a new and better way to Program CNC Machines.

Setup & Run First Part CNC Setup CNC Programmer Program Tool Path The Solution: Machining Dynamics Information (Stable Speeds) 99.9% of manufacturers have no way of knowing the Stable SPEEDS of each “Cutting System”. For a programmer with limited machining experience, the first ‘educated guess’ could be from a handbook or the internet. Know the Stable Speeds (Green = Stable) (Yellow = Unstable) STABLE PREFERRED SPEED Solution Results Decrease in setup time Skilled resources focus on other variables (coolant, programming strategies, etc.) Increase tool life, eliminate chatter & tool breakage Better surface finish & tighter tolerances Decrease in cycle time

Discover a new and better way to Program CNC Machines. Setup & Run First Part CNC Setup CNC Programmer Program Tool Path The Solution: Machining Dynamics Information (Stable Speeds) 99.9% of manufacturers have no way of knowing the Stable SPEEDS of each “Cutting System”. For a programmer with limited machining experience, the first ‘educated guess’ could be from a handbook or the internet. Know the Stable Speeds (Green = Stable) (Yellow = Unstable) Information Resources STABLE PREFERRED SPEED Machining Dynamics

Tooling Rep Information Resources 30 Years Experience Discover a new and better way to Program CNC Machines. Setup & Run First Part CNC Setup CNC Programmer Program Tool Path OLD WAY vs. NEW WAY 99.9% of manufacturers have no way of knowing the Stable SPEEDS of each “Cutting System”. For a programmer with limited machining experience, the first ‘educated guess’ could be from a handbook or the internet. Know the Stable Speeds (Green = Stable) (Yellow = Unstable) STABLE PREFERRED SPEED Machining Dynamics

Discover a new and better way to Program CNC Machines. Implementation - Simple, Fast, 3 Step Process 3. You Utilize 1. We Collect 2. We Analyze 10 min/tool 5 – 50 min/tool Setup & Run Part Program Tool Path Improve CNC Milling

Discover a new and better way to Program CNC Machines. Decrease Cycle Time Know crucial STABLE SPEED information Eliminate Trial & Error End Result is optimal instead of acceptable 4.5x Improvement after 5 min ‘tap test’ Decrease Setup Time We guarantee a 30% average decrease Aerospace Manufacturer - 45% Military Depot - 85% Job Shop – 30 sec/part on 30,000 parts Increase Tool Life Small job shop saves $10k of Stainless Steel Eliminate chatter marks Decrease Scrap Die Shop stops chatter, saves $8750/yr Compare tools to determine best option Improve Spindle Life Improve CNC programming labor utilization Improve CNC setup labor utilization Reallocate experienced labor Supplement Scarce Labor Resources Big 3 Automaker– 4x longer spindle Life The Benefits / Success Stories

Discover a new and better way to Program CNC Machines. Cost Savings & ROI

Discover a new and better way to Program CNC Machines. Cost Savings & ROI We guarantee a 30% Productivity Increase These figures TRIPLE !

Discover a new and better way to Program CNC Machines. Learn More & Contact Us for Testing Website Videos Literature Media Articles Cost Savings / ROI Calculations Success Stories Call or Visit Us The Innovation Machine 30 S. Wacker Drive Suite 2200 Chicago, IL

Discover a new and better way to Program CNC Machines. Learn More & Contact Us for Testing Website – Next Steps TEST MY FIRST TEN CALL ME WEBCAST SIGNUP Call or Visit Us The Innovation Machine 30 S. Wacker Drive Suite 2200 Chicago, IL

Discover a new and better way to Program CNC Machines. Summary Simple 3 Step Implementation – Collect, Analyze, Utilize GUARANTEED to increase productivity by 30% Less than 15 minutes of internal resources per tool Works with your existing machines, tools, and software Affordable (only $250 per tool), quick payback, high ROI You don’t pay UNTIL and UNLESS you are 100% satisfied

Discover a new and better way to Program CNC Machines. Learn More Website Videos Literature Media Articles Cost Savings / ROI Calculations Success Stories Call or Visit Us The Innovation Machine 30 S. Wacker Drive Suite 2200 Chicago, IL