Dayton’s AFC Tool Sees “Incredible” Material Removal Rates
Dayton’s AFC Tool Sees “Incredible” Material Removal Rates, Decreased Cycle Time and Tool Optimization With VoluMill™ Ultra High-Performance Toolpath Engine.
DAYTON, Ohio – As a supplier to industries that demand near perfection in price-sensitive markets, AFC Tool, a division of FC Industries, is always on the lookout for ways to improve productivity, manufacturing processes and the bottom line. It found one way with the high-performance toolpath engine VoluMill™. Based in Dayton, AFC Tool is a single-source design, tooling and finished manufacturing operation that serves the medical, automotive, food and beverage, pharmaceutical, energy and aviation industries.
AFC strives to meet each client’s unique needs by using a flexible approach to find the right market-driven solution for a client’s problems. The company also prides itself on its communications with customers and quick project turnaround.
Prior to implementing VoluMill, AFC Tool used a 1-inch diameter Mitsubishi AJK high-feed insert cutter to rough the part at a material removal rate of 1.44 CIM with a feed rate of 103.1 IPM and a spindle RPM of 1,719. The end result was a cycle time of 13:29.
Seamless Integration with Siemens NX CAM
Using VoluMill seamlessly with its Siemens NX8® CAM system and a .625-inch diameter, 5-flute HEV-5 end mill from Helical Solutions, AFC Tool was able to increase the material removal rate to 5.89 CIM and up the feed rate to 158.3 CIM with a spindle RPM of 6,021. The bottom line is a cycle time of 2:45.
“These material removal rates – above machine and tool manufactures specifications -- are incredible,” says Barry Davidson, AFC Tool’s CAM Programmer/Designer. “Using 5-flute end mills we are able to move large quantities of material easily without sacrificing tool wear. We manage tool wear so mills are not just used once, but are sent out for sharpening before failure. The tools that we have had sharpened function just as well as a new tool. VoluMill has cut the tooling cost on projects.”
As important to AFC Tool as the reduced cycle time is VoluMill’s ease of use.
“User interface is same as in Siemens NX so there are no special terms to learn,” Davidson explains. “Because of that, the learning curve for implementing VoluMill has been very short.”
Davidson also reports that changes to a part’s CAD model are easily updated to geometry changes within VoluMill. Engage feed/speeds and non-cutting moves are all figured internally with the path so there is no need to edit.
Bringing VoluMill into its operation allows AFC Tool to be more flexible, allowing support machine tools to rough out large parts for molds, dies and other fixtures, freeing more-refined CNC machines for more intricate projects.
VoluMill - Proven Success
“VoluMill’s proven and constant material removal enables programming for almost any machine at the facility,” Davidson says. “This enables “hot” jobs to be roughed as soon as any of our three-axis machines come open.
Part Description: Assembly and gauge yoke details for tubular assemblies