Material removal rates (MRR) is the term for the measurement regarding how much material is removed from a part during machining over a set period of time. Material Removal Rate is the key identifier in machine tooling efficiency, as well as the efficiency of both CNC machines and softwares. Radial depth of cut (RDOC) and axial depth of cut (ADOC) are critical elements to MRR, as this determines how and where your tooling is engaging with the workpiece. Applying High Efficiency Milling (HEM) strategies to your milling practice is the best place to start to increase MRR while also keeping tool wear and overall tool life in check.
Utilizing HEM with Helical Solutions’ HEV-C-6 chipbreaker with Mastercam software, Makino machinists were able to use a Makino PS105 VMC to achieve a new industry standard in MRR for 4140 steel alloy.
Setting a New Material Removal Rate Benchmark with Helical
Engineered for High Efficiency Milling (HEM), Helical’s HEV-C-6 was designed for optimal chip evacuation and reduced tool harmonics at high RPMs. Makino machinists utilized these features alongside Mastercam’s highly effective tool paths to create an astonishing material removal rate.
Watch the video below from Makino to see these impressive feats.
Inside the machine, the HEV-C-6 was spun at 10,695 RPM with Mastercam’s impressively efficient toolpaths to achieve and incredible 40in3 MRR.
Harvey Performance Company National Application Engineer Don Grandt, who worked with Makino and Mastercam on this project, spoke of what went into this effort.
How did this project initially gain traction?
A Helical Solutions e-mail seen by Makino that highlighted our new HEV-C-6 end mill. They wanted to work with us and Mastercam to do a demo to show off the power of their PS105 Vertical Machining Center with a 1/2″ end mill. Using our tool, they were able to max out the horsepower on the machine to get unbelievable MRR rates.
What considerations were met as you attempted to set this new industry standard?
All tools can only be pushed to the limits of the machine and material. So the goal was to watch the machine’s spindle load to give 100% or greater efficiency of the machine. We also wanted to use a combination of radial step over, axial stepdown, and Feed per Minute to maximize the MRR as well.
Why was Helical’s HEV-C-6 chosen for this project?
The tool was chosen for a couple of reasons. First, the email that Helical sent was boasting some impressive things about this tool, which intrigued Makino. The other reason was Mastercam was working with us in the past and kind of had an idea that with they tool path (Dynamic) and Makino’s machine power and performance, that this could be an incredible collaboration.
What is next for the performance between these three brands?
We have pushed the limits of the Makino PS105 Machine with a half inch endmill so the sky’s the limit with other machines in Makino’s arsenal with greater horsepower and performance. And as far as Mastercam is concerned, they evolve their software yearly with new tool paths and strategies that make it easier and easier on the tool.
For more information on this impressive feat, a webinar hosted by Makino, and featuring Don Grandt, can be found here. Cutting Tool Engineering (CTE) also featured this collaboration in their August 2021 issue as well as in an accompanying blog post written by Jesse Trinque of Mastercam.