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GENERAL TIPS FOR BETTER TOOLING PERFORMANCE
How to get best performance from spiral router bits:
- Run them as fast as your application, the material and your machine will allow it. The faster they run the longer they will last.
Example: Compression spiral bit ½”x1”x3 S=1/2” routing Melamine needs a minimum of 400 IPM in order to perform well and last 20,000 – 30,000
lineal feet, or approx. 60-100 melamine sheets!
Same tool running at half the feedrate (200 IPM) will get dull in less than half the time.
- Rule of thumb: Spiral Bits need to run minimum of 200” (5 m/min) per minute per flute – therefore 2-flute tool min. 400 IPM
(10 m/min), 3-flute tool min. 600 IPM (15 m/min).
Don’t make dust – make chips!Do not forget: The worst enemy of carbide is heat
Which type of tool is best to use on machining centers:
- That will of course depend on the type of feed Rate and quality of cut you need to achieve:
What is chipload and why is it important?
Chipload is the actual thickness of chip that is produced in the machining process. Chipload is measured in thousandths (i.e.: 0.010) and is influenced by
the spindle speed and the feedrate of a CNC machine. The number of cutting edges on a router bit determines how the chipload is divided. A single edge
(Z1) tool takes all the chipload during a revolution, while a double edge (Z2) tool divides the load over two edges. Chipload is an important factor in tool
life because it dictates how much heat will be carried away from the cutting edge. Better heat dissipation directly relates to increased tool life. The
formula for determining chipload is: chipload= feedrate/(rpm x #cutting edges).
Feed Rate comparisons based on a 1/2x1x3-1/2” tool:
a) Brazed carbide Router bits: maximum 150-175 IPM (3,8-4,3 m/min) per flute
b) Insert Router bits: maximum 150-175 IPM (3,8-4,3 m/min) per flute, always depending on tool design.
They are slow running tools, because most have 1 flute only
c) Diamond Router bits:
maximum 180-200 IPM (4,5-5 m/min) per flute, always depending on tool designd) Spiral Router bits:
minimum 200 IPM (5 m/min) per flute. They are fastest running tools, made of solidcarbide or HSS having no brazed tips, or screws holding insert knives in them
Toolholder and collet maintenance:
- Use only CRC TEFLUB – dry lubricant spray for Toolholders and or collets
- Use only Kluber Lusin Lub – oily lubricant for inside the spindle
- Change collets periodically – they have a lifespan of about 600 working hours
- Keep the collets dry! They should be protected while in storage, but clean and dry for use!
- Toolholders have a lifespan of about 5-10 years depending on maintenance
- Remove build up with every tool change on tool shank, collet, internal taper of spindle, and internal thread of collet nut
- Watch for metallic damage on collets and collet nuts
- Most of all make sure the tools are clamped correctly at 92 ft/lbs, thus ensuring true running of the tools
- Incorrectly clamped tools will vibrate, and ultimately break
Clean tools last longer:
- Before using a brand new tool, spray it with “PAM”. Why? PAM will provide protection from rust marks, and pitch build-up. It will be easier to clean
the tools, which have been sprayed with PAM. Clean tools will last longer!
- Most tools in use today are made of either brazed carbide, solid carbide or carbide Inserts. Carbide does not like the pitch build-up, because it
contains tannic acid, which corrodes carbide, thus dulling/deteriorating the cutting edge.
- PAM can be used on any other steel surface that needs protection from rust or pitch build-up.
- Do not use PAM on toolholders or collets or spindles!
- WD40 is a good cleaner if the tools have minor pitch buildup. If the tools need major cleaning use 1 tube of Lye on
5 gallons of water, and soak the tools for a while. Afterwards brush them gently with toothbrush or similar.
Never use a steel brush, as it may damage the tools. Rust marks can be removed with Stain Remover.
If the pitch buildup is difficult to remove, you can use Oven cleaner spray, but do not leave it on for long, because it will corrode steel. Wipe the
tools off and protect them with T-9 steel protector.
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