Designing a Machining Process for Optimal Cost and Minimal Waste
In this time of limited material availability it is even more critical that machine shops minimize waste and optimize material efficiency. Not only can we not afford to do a job twice, often times we cannot find the material to do the job twice. So, how can we maximize our opportunity for success?
There is also a second concern that may be “new” to the machining industry, or at least realized with a greater clarity and urgency: qualified human resources, like materials, are scarcer than in previous years.
We should consider designing our processes for minimal operator frustration. Nothing frustrates a machine operator more than a machine not working like “it is supposed to.”
We recommend this strategy for customers that are designing a machine process for highest efficiency and total lowest cost and possible lights out applications.
Quality Raw Materials Insure Predictability & Consistency
As a first step, we recommend that customers start with high quality raw materials like Swiss Steel stainless steel barstock and Laurel Steel carbon steel barstock. Certified Grinding stocks products from both of these mills in several diameters.
The key to an efficient process is predictability and consistency. If you start with quality raw materials you can be sure that each bar machines like the previous bar. Therefore you can set your speeds and feeds and feel confident that your machine will operate in a stable process at maximum efficiency.
Avoid Getting Stuck In A Jam
We also recommend that at least one end of the barstock be “chamfered,” where the bar’s edges are cut to insure a smooth transition of the bar into the machine.
Chamfered end minimizes the possibility of having a machine jam. There are few things more frustrating for a machine operator than having a machine continually jam because the barstock is sawcut and maybe not perfectly straight, which brings us to the next recommendation…
Let’s Get It Straight
We recommend that the barstock be straightened. A straight bar will not only load into your machines more reliably but it will also prevent whipping. Whipping can cause finished products to be out specification which can create a significant amount of scrap that no one can afford at this time.
Keep Tolerances Tight
Lastly we recommend using centerless ground barstock. At Certified Grinding & Machine we can grind barstock to as tight as .0002”. For Swiss machine operation we recommend a tolerance of .0005”. A nice tight tolerance ensures that collets won’t jam and they won’t lose their grip maximizing your prospects of lights out operation and minimizing total operational costs.
To Summarize
So, in summary to maximize feeds, speeds, tool life and overall efficiency and minimize waste and operator frustration, we suggest that you purchase materials from a quality mill, like Swiss Steel and Laurel, that is chamfered, straightened and centerless ground.
If you analyze the total cost of your operations that you will agree with us that this is the most cost effective strategy for operating your machining centers.
ISO 9001 accredited Certified Grinding & Machine is a leading provider of precision ground bars and parts for the most demanding of machining applications in a variety of industries, grind tens of thousands of bars and millions of parts to extremely tight tolerances and superfine finishes each year for its customers throughout North America. Contact us to learn more.
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