Best Practices for Extending the Tool Life of CNMG Inserts
The life of the tool is integral to productive, efficient, and cost-effective CNC machining. CNMG inserts are particularly unique from other cutting tools used for turning metals, as they have been designed for both durability and precision. However, even the best insert will not be used under the right conditions and will not reach its full potential without knowledge and care for the insert. Here are some excellent ideas you can implement to maximize the tool life of inserts:
1. Understand the Specifications of CNMG Inserts
Understanding the specifications available will help with the use of CNMG inserts. Upon opening the package you will see a code specific to that insert that indicates its features, such as shape, edge features and specifications or tolerances, and clearance. Understanding the specifications of inserts will assist you in the selecting of the proper tool for a material and/or operation. Tool grade and coating are also important factors for inserts in relation to tool life when cutting hard metals.
2. Select the Suitable CNMG Insert Type
There are various types of inserts based on the machining application. They vary in insert geometry, chip breaker design, and coating materials. A tool designed for roughing would be suited with a robust insert that has a thicker cutting edge and a high-strength coating. Finishing operations would utilize a sharper edge insert with a precision-ground form. Choosing the correct type of insert minimizes the potential for over-shank breakage while balancing surface finish expectations and tool life.
3. Normalize Cutting Parameters
All things being equal, cutting speed, feed rate, and depth of cut are three of the primary influence factors in determining the life of the insert. Running the insert too quickly will also build unnecessary heat, which leads to premature wear at the cutting edge. If the insert is run too slow, the chips will not form properly, and the cutting operation will be inefficient. Always return to the manufacturer recommendations for ideal cutting settings. The cut or feed rate also needs to be adjusted based on the material hardness and the insert grade to yield consistent results or life of the tool.
4. Keep Correct Insert Angle and Setup
Setting up the tool is another fundamental factor impacting insert life. Using the correct insert angle during tool setup can help minimize vibration, reduce chipping, and extend insert life. Generally, the optimal approach angle is a range of 75° to 95°, depending on the application. It is important to orient the insert correctly against the workpiece surface to provide cutting stability and smoother finishes. Inadequate alignment can significantly affect insert life, even with slight misalignment.
5. Make Sure Tool and Workpiece Surfaces are Clean
Contamination and debris between the CNMG insert and tool holder can lead to improper seating and unequal cutting. Always clean both the insert and holder surface before installing. Continue to check the holder pocket for damage or debris buildup. The more secure and clean the fit is, the better the will be at being stable, leading to reduced wear and increased accuracy.
6. Use Proper Coolant and Lubrication
Coolant and lubrication are key to improving tool life, especially during high-speed machining. The right coolant minimizes heat buildup, making chip removal easier. If the coolant flow is steady, it will prevent thermal cracking in the insert and improve surface finish. Both flood cooling and mist systems must reach the cutting edge of the CNMG insert.
7. Replace Inserts in a Timely Manner
If you wait too long to change an insert, you may cost yourself damage to the tool holder and the part. Check for wear patterns often and replace inserts when the edges are dulling. chipping, or rounding. Replacement before you get too much wear helps build a consistency factor into your cutting tool performance and prevent being surprised by tool failures when machining production runs.
Summary
To optimize the tool life of a CNMG insert, a union of knowledge, accuracy, and upkeep is essential. Knowledge of insert specifications, the appropriate type of insert, good insert angle maintenance, and correct operating practices can all greatly improve tool life and machining quality.
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FAQs
- What is a CNMG insert?
An insert is a type of cutting tool for CNC turning typically used for machining steel, stainless steel, or cast iron.
- How do I increase the life of a CNMG insert?
Employ the correct speed, feed, coolant, and insert angle, and ensure that the tools are regularly cleaned and worn insert tips are replaced promptly.
- What does a CNMG insert specification mean?
The specification defines the shape of the insert, its clearance, and tolerance, as well as the type of chip breaker for accurate machining.
- What are common types of CNMG inserts?
insert types will vary by coating, grade, and chip breaker design for either roughing or finishing operations.
- Why is the angle of a CNMG insert so important?
The angle can ensure stable cutting and less vibration while protecting the insert from wear.