MetalMax provides a Stability Diagram that MAPS the ideal RPM to stay away from Chatter and Resonance while providing the Maximum Material Removal Rates. It uses a technique known as Modal Analysis (Tap testing) to determine the structural characteristics of YOUR tool/holder/spindle stack-up. Harmonizer uses a patented Audio technique to listen to your process to analyze the chatter and recommend a more stable RPM.
What type of metal-cutting operations are most common? Milling tools are the main focus, but turning and boring are also done. Reaming and Drilling is typically performed by our expert consultants.
How long does it take to make a Stability diagram? Less than 10 minutes: about 5 minutes to input your tool and machine info, and about 5 minutes to Tap Test your Endmill.
Do I need to cut at High-Speeds? No, high-temp alloys such as titanium have been improved; however, it is true the faster the RPM the greater chance of success. Medium to large CNC machines over 15,000 rpm are rarely run at optimal speeds and feeds for maximum MRR or quality, so this is a large percentage of customers.
We don't have chatter, so how can it help us? Most machinists and engineers can eliminate chatter; HOWEVER, the cost to do so is most often loss in Productivity, as the process is slowed down. On average, if we optimize your 10 most utilized endmills, you will increase these tools productivity by 30%.
This is great for a production shop, but we rarely cut even 20 of the same part? True, but do you reuse the same tools? Most shops have their favorite 5-10 tools that are used for nearly 50% of their milling. If we optimized your favorite 10 tools and improve them 30%, that is 15% less time a machine cuts metal. If you run 20 hours a day, that is like 3 free machining hours a day. At $100/hour machine time, that is $300 a day, $1500 a week, and $75,000 a year. One of our customers optimized a single endmill where the MRR obsoleted nearly all othe tools, so they removed 70% of their metal with 1 tool.
We have a 25,000 and 36,000 rpm spindle that we run at Maximum RPM, so how can we improve? These speeds offer the biggest advantage, as they are fast, BUT the MAX RPM is rarely the most productive for Metal Removal Rates.
Example 1: 3/4" Carbide 2 flute at 25000 rpm cut 3.8 mm ADOC (Ap) - After MetalMax - 23,572 rpm with 6.35 mm ADOC. A 57% gain with constant 0.1 mm/tooth feed.
Example 2: 3/4" Carbide 2 flute at 36000 rpm cut 0.4 mm ADOC (Ap) - After MetalMax - 19,282 rpm with 1.27 mm ADOC. A 70% gain with constant 0.1 mm/tooth feed.
We are a small shop and can't RISK using high-tech gadgets? The theory used in MetalMax has been around since the 1950's, and used in industry since the late 1980s. The techniques are not Risky, but exactly the opposite, as KNOWING where to run your process allows robust parameters to be used. Small shops have a lot to benefit, as it is easier to implement techniques with fewer people. Our smallest customer has 2 Haas VMC and 1 Enshu HMC, and the first endmill optimized saved them over $6000 in the first year of productivity!