SME Tooling/Cutter Edge Radius Study Project

Machining/Metal Removal TechnicalCommunity
Deburring/Surface Finish Technical Group

Submitted by Jack R. Clark, Surface Analytics, LLC
and Colorado State University, Mechanical Engineering Dept
16 March 2011

1. Background
1.1. For many decades there has been an awareness of cutting tool edge condition and tool surface finish and the effect it has on piece part quality and tool life. There have been many independent studies, tests, and implementations of edge conditioning methods to create extended life in turning, drilling, and milling cutter tooling – some published but most kept “secret” as a manufacturing advantage.
1.2. The “Deburr/Finish Tech Group” of the SME has tasked itself to manage the project and use it’s member resource pool to provide tooling, applications, and the necessary documentation and reporting to objectively test cutting tool edge radius improvement on tool life and piece part consistency. This is a proposed outline on how to organize and conduct such a test. It is the intention of the participants to publish a document, possibly an SME Technical paper or article, at the conclusion of the study.

2. Goals
2.1. Confirm that edge and finish conditioning improves tooling life and potentially also improves performance values in tool speed, feed speed and substrate surface finish and helps prevent part surface finish deterioration from tool wear over extended periods of time.

Project Contact Information:

Jack Clark
Surface Analytics, LLC
Correspondence: PO Box 71
Shipping: 8543 North County
Road 27
Masonville, CO 80541
Cell: 860.575.7500
Fax: 832.575.7504

Jack Clark (2)
Colorado State University
Department of Mechanical
1374 Campus Delivery
Fort Collins, CO 80523-1374
Office: 970.491.4382

Dave Davidson
Deburrinnng Solutions
7609 N. Hughes Drive
Spokane WA 99208
Cell: 509 230 6821

3. Proposed participants
3.1. Mackay Manufacturing – supply the test tooling, machine a selection of piece parts, and gather tool life and piece part data.
3.2. Mass Finishing, Inc. – supply the finishing process(s) to condition the tooling for testing.
3.3. Machining Efficiencies, Inc. – consult on test format, measurands, and result analysis.
3.4. Dave Davidson – SME liaison, general test organization, processing advise.
3.5. Surface Analytics – general test organization, tooling and piece part documentation, processing advise, results analysis
4. Proposed Tasks
4.1. Select a known, repeated “high volume” piece part
4.2. Select a milling operation that has tool usage history and is typically consistent in tool life
4.3. Select the milling tooling
4.4. Document “as supplied” tooling condition
4.4.1. edge radius at predetermined positions
4.4.2. surface finish at predetermined positions
4.4.3. all dimensional characteristics critical to tool performance
4.5. Centrifugal Barrel Finish (CBF) the tooling
4.5.1. establish process parameters
4.5.2. process the test tooling
4.6. Document “finished” tooling condition
4.6.1. edge radius at predetermined positions
4.6.2. surface finish at predetermined positions
4.7. Perform “Life” tests on tooling
4.7.1. determine what machining parameters will be monitored
4.7.2. run “as supplied” tooling as a test control
4.7.3. run “finished” tooling tests
4.7.4. save all tooling whether failed or not for documentation
4.7.5. save a sampling of piece parts for documentation
4.8. Document “all” post machining tooling condition
4.8.1. edge radius at predetermined positions
4.8.2. surface finish at predetermined positions
4.8.3. all dimensional characteristics critical to tool performance
4.9. Document all piece parts
4.9.1. finish
4.9.2. defects
4.9.3. dimensional
4.10. Complete “Tooling Test Summary” spread sheet – see attached (Appendix A)
4.11. Complete the “Edge Radius Study” report including:
4.11.1. piece part drawing(s) indicating the surface(s) and profile(s) being machined by
the test tooling
4.11.2. test tooling part number(s), supplier(s), and specifications
4.11.3. list all tooling documentation methods, setups, and callouts measured
4.11.4. list all CBF setups and process conditions
4.11.5. list all machine tool setups, conditions, and observations


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