Dormer Tools boosts tooling performance further with Open Mind hyperMAXX

As Dormer Tools machining applications engineer Matt Johnson explained: "I was invited by an Open Mind engineer to supply tooling for a demonstration piece at Warwick University and witness the benefits of the new hyperMAXX package. "Using Open Mind's hyperMILL, the previous machining time for the 18 mm deep pocket in the 316 stainless steel part was 25 minutes. I supplied our S356 solid carbide end mill and changed the cutting parameters to slightly reduce feeds and speeds, but machine the full 18 mm depth in one pass, as opposed to the previous program that used three 6 mm deep passes. This strategy reduced the cycle time. "Then the Open Mind engineer turned on the hyperMAXX roughing cycle and asked me to treble the recommended Dormer feed and almost double the speed rates for the cutter. My apprehension was quelled by the confidence of the Open Mind engineer and we immediately witnessed a staggering result." Most cutting tool manufacturers measure productivity benefits by calculating the QMax value for the machining cycle, this cubic (cm/min) value is the depth of cut X step over X feed divided by 1,000. "In this demo, the original QMax value was 17.1 ccm/min, using the Dormer 12mm cutter at the recommended parameters resulted in a QMax value of 30 ccm/min - a significant gain. However, when the hyperMAXX module was turned on, it gave us a value of 108 ccm/min, a staggering 280% improvement on the combined use of hyperMILL and Dormer tooling. Compared to the first test piece, the result was a 630% improvement," Mr Johnson highlighted. In addition to improved performance, cutter wear was less than the previous cycle. "We are currently machining a structural wing component from titanium for an Open Mind and Dormer customer. Like the Open Mind customer, we are using the same Dormer S357 12 mm carbide cutter with a 3 mm radius and X-Ceed coating and we have extended tool life from 30 minutes to over 2 hours – a tool life improvement of over 200%. The only difference is that we are using hyperMAXX." The customer was taking 40 hours to machine two sides of the component; Dormer has reduced the machining time to 10 hours with hyperMAXX. As Mr Johnson said: "The aerospace subcontractor has a contract to produce over 150 parts that was taking close to a week to machine each part - we have now cut that production time drastically! The component has a number of pockets on each side and to demonstrate cycle time reduction with hyperMAXX, one pocket was previously machined in 40 mins. Dormer is now milling the pocket in 3 minutes. To achieve such a result and simultaneously improve tool life is exceptional." See also Machinery article on hyperMAXX and other such CADCAM technologies