Tool cost improvements are typically 15% to 20%.
Similar improvements in quality and uptime.
Gary Rodak, CMfgE
Gary.Rodak@MachiningEfficiencies.com
www.MachiningEfficiencies.com
Phone: 734-904-4060
This program is presented at several SME technical clinics; Broaching Technology clinics, the Process
Improvement Clinics and the Basic and the Advanced Gear Design & Manufacturing clinics. www.SME.org
This program is also presented at the Michigan Manufacturing Technology Center in Plymouth, MI seve
times each year. www.MMTC.org
This presentation is best viewed in the Powerpoint Presentation mode.
Machining Efficiencies, Inc. is dedicated to improving the
manufacturing performance of machining and grinding
operations.
We focus on improving our clients profitability by identifying
specific corrective action that will reduce the process costs.
We transfer our knowledge of process improvement
techniques to our clients to ensure long term effectiveness.
We accomplish this through educational seminars and first
hand exposure to best practices.
Gary Rodak, President
“We involve you.”
 We hold several one hour classroom reviews of basic machining
process theory and the relationships between filtration, cutting fluid
chemistry, biology, and metallurgy.
 These sessions also cover best practices for machining and grinding
processes, coolant control, filter maintenance and metallurgy.
 We utilize your specific or familiar floor problems for customized
training programs and implementation of best practices.
 Our recommendations are reinforced with customized presentations
and reports suitable for quality system audits.
 Available follow up reviews ensure long term implementation of best
practices and problem resolution.
 We stay focused and are driven to reduce your cost of manufacturing.
Skill Enhancement Program for Engineers & Machinists
 We introduce your Engineers and Machinists to practical
techniques for quickly improving process performance.
 We show how the worn tool indicates the process
conditions and what may be sub-optimized practices.
 The Program uses familiar tools and processes that
benefit from the attention.
 Simple, easy-to-create reports are used for follow up and
for quality system audits.
 The exposure to this problem solving technique will be
used by the students for the rest of their professional
career.
Topics addressed in the training program and how they relate to each other
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9 elements of making a good part & why all are important
Types of metalworking fluids and control parameters
Chemistry – how additives work and what you need to know
Boundary and hydrodynamic lubrication modes
Orthogonal geometry in machining
Plane of deformation during cutting – controlling it for efficiency
Microfinish – how it is created and controlled at the cutting edge
Filtration – how much do you really need?
Biological activity – the impact on the machining process
Coolant system problem identification and resolution
Tool wear patterns and how to read them to improve the process
Tool wear patterns – cause and cure with broaches, inserts, hobs,
shapers, reamers, drills, etc.
 Tool life improvement and practical techniques (customized program)
 Tool condition and sharpening techniques (customized program)
 The costs of manufacturing at a specific point in the total process
Sequence of events for a plant wide* process improvement program.
Overview
 Identify top 15 to 20 high cost tools or high volume tools
 General audience classroom training
 Identify tool and coolant system issues
 Investigate issues and root causes
 Present findings, reports and recommendations
 Incorporate improvements into standard operating procedures
 Follow up key issues and findings
*A plant wide program has the greatest impact on costs and involves the
greatest number of individuals who can affect the processes.
Following are some slides taken from the presentations.
Technical Program
A Practical Approach to Improving your
Machining Operations
Coolant Action in the Cutting Zone
Tool Wear Patterns
How to Adjust the Process for Improvement
Troubleshooting Coolants in Central Systems
Machine a better chip……..
It is the core of your business
1. Reduce the cost of manufacturing
A. With greater tool life. (Lower tooling costs)
B. With less tool change set ups. (Less downtime)
2. Improve the surface finish during the machining
processes.
A. More accurate form generation.
B. Attain tighter tolerances.
C. Better subsequent processes. (Better coating, assembly, etc.)
D. Less residual compressive stresses in parts.
“All FIVE disciplines are related and mutually influential”
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Tools
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Metallurgy
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$ Coolants
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The Costs of Manufacturing
Filtration
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Machine
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Identify ALL the Problem(s) with your central system
(“Poor tool life or wheel life are used as examples here.”)
A. Odor
B. Rust and Stain
C. Loss of filter efficiency
D. Poor emulsification
E. Residual films
F. Dermatitis
G. Foaming
H. Poor tool life or wheel life
I. Poor microfinish
J. Poor part size control
K. Paint removal
L. Smoke or excessive misting
M. Clinkering of chips or swarf
N. Fungus
O. Seals or V Belts
P. Chip nests (stringy chips)
H. Poor tool life/wheel life
(These 20 influential components are investigated.)
1. Concentration control
2. Microorganisms/fungus
3. Biocide levels
4. Wrong product choice
5. Improper speeds and feeds
6. Wrong tool material choice
or wheel material choice
7. Improper resharpening or
redressing
8. Misdirected coolant flow
9. Pump sucking air
10. Restricted coolant flow
11. Foam
12. Contamination by hydraulic
fluids, way oils
13. Contamination by floor
cleaners or machine
cleaners
14. Incorrect tool design/wheel
application
15. Incorrect metallurgy of
parts
16. Part fixturing
17. Part gauging
18. Prior part processing
19. Filter malfunction
20. Machine/spindle vibration
Failure Modes of inserts
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Built Up Edge phenomenon
Chipping Wear
Flaking
Spalling
Fracture
Flank / Nose / Face Wear
Notching Wear
Thermal Cracking (Shock) (Fatigue)
Crater Wear (Diffusion Wear)
Deformation Wear
Cobalt Leaching
All of the failure modes are documented with microphotographs for future
reference. There are four more failure modes associated with broaching,
hobbing and other similar processes. They are not included in consideration
of the document file size.
Chipping Wear
Identification & Causes
 Identification
– Ragged edge on insert
– Poor (streaked) surface finish on parts
– Irregular wear
– Leads to catastrophic tool failure (masked cause)
 Causes
– Excessive loads on tool
– Built Up Edge (BUE)
– Intermittent contact with hard inclusions
– Machine or part fixture vibration
– Lack of rigidity of tool holder setup
– Improper selection of insert geometry / substrate / coating
– Re-circulated fines / micro particles in coolant
– If coated, coating may be too thick
Chipping Wear
Cure
 Cure
– Aim coolant properly
– Reduce Tramp Oil content in coolant
– Use coolant with Extreme Pressure (EP) additives
– Make sure the machine or fixture does not vibrate
– Balance spindle
– Strengthen tool holder
– Select insert with high cobalt content
– Decrease feed rate
– De-scale surface of part
– Improve filtration – positive barrier
– Change coating (if used) or eliminate
We tailor the cure to the specific issues requiring improvement.