Milling optimisation as a service

Kistler is following up its collaboration with Productive Machines by offering a new service for milling applications. It uses specialised software for combined analysis of data from physical measurements and NC machines.

The benefits of the service include optimised cutting parameters that help reduce chatter vibrations, improve the quality of manufactured parts, and cut overall costs.

In machining applications, unwanted vibrations on structures cause multiple negative effects. They can impact component quality (dimensions, surface, etc), limit productivity, and decrease tool life, leading to faulty parts and additional reworking as well as higher costs for materials, tools, machines and engineers. To avoid these problems, Kistler is now offering a new milling optimisation service in collaboration with Productive Machines, the UK-based cutting force expert.

The basis for this service is a dynamic stiffness analysis of the machine tool. The physical optimisation phase (known as the ‘tap test’) can be accomplished with impulse hammers and accelerometers from Kistler; this is followed by an analysis of the customer’s NC program, performed with new software from Productive Machines. All the acquired data is then processed to create a new NC program which, once installed, ultimately leads to better cutting performance, longer tool lifetimes and higher OEE – to name just a few benefits.

Although the milling optimisation service has only been available on the market for a short time, customers in many industries have already discovered its major advantages. Successful use cases include applications in the automotive, aerospace, mould-making, precision parts and medical technology sectors.

As an example, a French car manufacturer facing challenges with a machining process for a gearbox housing, the optimisation service provided a solution that led to shorter cycle times and reduced tool wear. Also thanks to the new offering, an aerospace supplier based in Spain benefited from less chatter, fewer damaged parts and overall cost savings of 25 percent. And last but not least, a UK-based mill/turn specialist was able to optimise production of an aerospace part with the help of the new service: in this case, applied maximum forces decreased from 2,000 to 1,000 N and cycle times were shortened by 13 percent.

The new milling optimisation service is available either onsite (when experts from Productive Machines visit the customer) or remotely in digital form via a credit-based online platform. Customers who choose the remote option conduct the dynamic stiffness analysis themselves, and then upload the CAM files to the platform.

Buelent Tasdelen, business development manager at Kistler, comments: “Our new milling optimisation service will benefit mould-makers, machine builders, manufacturers and OEMs in many industries: it gives them exactly what they need to improve their machining processes.

“By largely eliminating vibration, customers enjoy advantages such as higher product quality, longer tool lifespans and shorter cutting times – so they can significantly boost their productivity and OEE while cutting their production costs.”