Kyocera SGS Precision Tools advises customers not only on the correct cutting tool for specific applications but also on the best machining strategies.

For some applications, such as PH stainless-steel hydraulic cylinders and a number of aerospace components, Kyocera UK sales manager Tony Theaker says the only way to cut them successfully is to use a long end mill and Edgecam’s Waveform roughing strategy (www.edgecam.com).

Mr Theaker says: “Edgecam’s flexibility means we can use our cutting tools in the most efficient manner to get the best-possible results.

The way the software controls the radial engagement of the tool is particularly important, allowing us to push the tools with high feed and metal removal rates, knowing that we will get a constant cutting condition.

Most CAM software will ‘load up’ in the corners, causing the tool to possibly fail, so the cutting parameters have to be slowed down. However, Edgecam’s Waveform roughing keeps a constant radial engagement, allowing you to push to the maximum.”

Kyocera’s technical manager, Barry Ward, says: “We take customers’ machining challenges off their hands and provide solutions by applying all our cutting-tool, machine and software knowledge.

“This is done through in-house trials, process optimisation, time studies, machining-strategy studies, and consideration of tool and part design.

“The component may come in from the customer as a model, and our first step typically is to do a time study where we try to optimise what they’re already producing — and give recommendations on tooling.

“The next stage is where we actually cut the component and try different Edgecam strategies to come up with the best result.

“Further trials may be required at the customer, so we’ll take our engineers on-site and support the customer through the whole process.”

He says the company also designs special tooling for specific applications when required. These are tested on a GROB G350 horizontal machining centre at its Tech-Hub in Wokingham.

Mr Ward cites the example of a particularly thin component that had to be machined unsupported. “We worked closely with Edgecam to produce a bespoke program and developed custom tooling specifically for this particular component.”

Aerospace technologies manager Ray Gibbs, who works mainly with large Tier One and Tier Two aerospace companies, says: “I give them a sequence of tools that we’d recommend to optimise their processes, then we simulate the tool-paths with Edgecam and show them the cycle times and material removal rates.

I carry out a demonstration — on-site or on our own GROB — and video the test part being cut and the tools used. Either way, the customers see that the combination of the right cutting tool and Edgecam strategy optimises their CNC machine tools. Edgecam’s Waveform roughing strategy also improves tool life, particularly when machining titanium.”

Kyocera’s EU marketing manager Jose Ucar sums up by saying that Waveform increases a manufacturer’s productivity and tool life.

“Edgecam’s high-efficiency machining techniques engage the full cutting length of the tool, achieving a more efficient cut, which has a direct effect on tool life; and the ability to ramp up feeds and speeds gives improved material removal rates and shorter cycle times.

“Customers are usually delighted with the results, as they have a cost-effective strategy in terms of cycle times and process security.

“Consumable costs are also reduced, as the Waveform strategy means that the end mill has worn down evenly, rather than being damaged by overloading in the corners.”