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Frequently Asked Questions Q: What type of tool is the most cost effective in doing straight or contoured cuts, with a solid or composite core and a single or double sided laminate material? A: There are three types of tools offered, each with a different design. It all depends on the equipment, material used and part size. An Insert tool machining a particle board substrate with Melamine surfaces, with a 3/4"(19mm) can cut at feeds speeds (1/2", 12mm tool) at 250IPM at 18,000 Rpm's. The Insert knives will require changing between 3-4 hours, a relatively inexpensive cost. A PCD (Diamond) tool can machine, (with the above perimeters) at 275IPM, at 18,000 Rpm's. This tool should last one or two weeks. There are a variety of designs, some which are disposable and are tossed after becoming dull, and some can be serviced 4 times or 8 times. A Solid Carbide compression tool (with above perimeters) can machine at 900IPM (or faster, depending on part layout) at 18,000 Rpm's. Tool life is 8-14 hours. A net gain in production is 2-3 times greater than a PCD or an Insert. A superior edge finish is also realized in this tool, along with reduced decibel levels. Using this tool provides with less machine maintenance, on the collets, spindles and bearings. Q: We are using a PCD Profile Router to machine an outside edge. Everyone we talk to says we can get longer tool life (100 times) vs. any other cutting edge. We do not get anything close to that. A:Courmatt feels 100 times longer is excessive in most cases. The number we normally use is 40 times the tool life. this allows us to justify the initial cost of the tool, eg., TCT Ogee PCD Custom $180.00 $1000.00 Service (4 x $15.00) 60.00 Tool still machining $240.00 TOTAL (8 tools) $1,920.00 (1 tool) $1000.00 New/Service $1,920.00 Service $200.00
To achieve longer tool life you must first use a ruffer and then the profile tool. In this way, you will get closer to your numbers of 100 times. Make certain the ruffer is at least 1/4" (6mm) smaller in diameter. This will allow the heat to dissipate the chips, allowing for longer tool life. Q: In one of your answers, you suggested that you run a ruffer and then a finishing tool. My question is would that not increase cycle time? A: If you have a machine that machines @ 400 IPM you are correct. If your equipment can achieve speeds of 600 to l500 IPM your cycle times are decreased and extended tool life is achieved. To machine .750 (19mm) material with a single pass profile, feed speeds would be under 350 IPM and closer to 250 IPM. If you used a ruffer, feed speed with this tool can be 1200 IPM and your profile tool can machine @ 600 IPM. Your profile tool will last 3-4 times longer between services, and you will net 30% parts being machined. (Refer to Technical Info) Q: We recently purchased a new CNC machine and are using standard off-the-shelf carbide- tipped tools. They seem to work, but we have had a few fires. We tried other tool manufacturers but with the same results. What do you suggest? A: This depends on whether you are ramping or plunging. I believe you are plunging with a straight router or a downshear tool. You have to understand there is more cubic inches of material being removed than you have in your gullet. If this is true, you have to peck 2 or 3 times to remove this material at a slow rpm (3000). Your best move is to ramp into your material 30^ minimum, regardless of the tool. This will assist in chip removal. Q: We do not have a tool changer and we need to do the outside perimeter and a groove with the same tool. A: An Insert tool or a Solid Carbide can be used. The Insert tool with a plunge tip or 4 cutting edges on the Inserts, which are standard on COURMATT's Insert shank tools. The other choice is to modify the CUD series for the depth of groove. Lets say you require a .500 groove with a depth of cut a .250, we modify the up shear portion at .200. This will allow you to achieve the feed speeds on both the perimeter and the groove. Q: We have a saw head (aggregate head) on our CNC. The manufacturer recommends the tool weigh no more than 8 pounds, but we have to V Groove .790 material and the steel tool weighs 10 pounds. What would you recommend? A: COURMATT offers an "ERGAL" Insert body weighing only 3.5 pounds. Depending on the diameter of this unit, usually at 160mm you can use 7200 Rpm's at a feed speed of 400IPM. This will provide you with 25,000 to 30,000 linear feet before the Inserts are reversed. A steel head weighing 10 pounds, will require spindle and bearing replacement much sooner. With insert tooling you have complete control of your production, as you require one tool, with only replacement Inserts. The Insert body will always maintain the same diameter and angles. Q: There are many manufacturers of Solid Carbide tooling, why would I choose one over the other. A: We at COURMATT believe our tools are superior in a variety ways, from the carbide grade and special designed carbide, to our overall tool length, our engineering professionals, and to the after market support [see Technical Information]. COURMATT markets these tools with a value added educational information to ensure the longest tool life possible, complete with a full CNC after market service facility. These tools run side by side with similar tools, will outlast any and all competitors. this is a internal link to training
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