Cutting Tools
Increase your speeds and feeds.
CNC machines are very rigid and you can push them to the limit. Increase the speed of the spindle and the feed rate, which is the rate of travel of the tool in the work piece. Maximize the speed of the spindle and the feed rate to get the job done as fast as possible. If your speed is too slow for your feed rate, your tool will break under pressure. If your feed rate is too slow, you are wasting time and your tool will wear prematurely. It is important to achieve the optimal speed and feed for the material you are cutting.
Use the same tool for finishing and roughing. The roughing process cuts away the bulk of extra material and finishing brings it to its final dimension while leaving an acceptable finish. By using the same tool for both, you eliminate the time it takes to change the tool. Each tool change adds to the overall time it takes to complete an operation.
Cooling
Keep your tool and your work piece cool during cutting. Since the cutting process produces immense heat, it is important to keep everything cool. Coolant is used for this and it is important that you have several streams going at once as the tools are often very different in size. By adjusting your coolant flow to hit all the tools in your operation, you can save them from wear and breakdown due to heat.
Re-Sharpen Drills and End Mills
Re-sharpen your drills rather than throwing them out. Most machine shops have bench grinders, used to re-sharpen any drills. Follow the drill shape and carefully re-sharpen your drills. This is an easy way to save money.
Re-cut end mills using a cut-off saw and table grinder. Like a drill, an end mill can be re-sharpened by cutting off the worn area and sharpening at an angle suitable for cutting. Place the end mill in a holder specifically designed to hold it at the correct angle and pass a grinding wheel over the cutting surface until an edge is created. Repeat the process for the other sides and you have a new end mill for cutting.
