Honestly, I was embarrassed to show those numbers when I first got them because I didn’t think they were believable.  But I have talked to so many customers since who confirm the results I just have to share them.

Milling insertspecification

We however do the equivalent of this every day on our shop floor, when we use inserts without thinking about the cutting edge geometry. Result ? Higher cycle time, lower product quality, higher tool costs.

The cutting edge looks the same on all inserts, and the fancy pattern on the insert looks like it is just for aesthetics. However, these are the equivalent of the axes and the kitchen knife – they are different for different workpiece materials and applications (roughing, finishing, etc.).

Turning inserts types

It’s pretty cool technology, it’s totally unique–nobody else is doing this.  And it uses state of the art Artificial Intelligence algorithms to solve the problem.

That’s how much difference you can get by optimizing the two variables that matter the most and playing offense rather than just defense.  If you’d like to know more about G-Wizard, check it out:

Insertclearance angle

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Bob is responsible for the development and implementation of the popular G-Wizard CNC Software.  Bob is also the founder of CNCCookbook, the largest CNC-related blog on the Internet.

Just understand the basics of insert cutting edges from this document and select the correct insert. It can dramatically reduce cycle time, improve quality, reduce tool costs, and improve profits in your CNC machining. The rules apply both to turning insert geometry and milling insert geometry.

Well, simply put, once you choose Cut Depth and Cut Width, you’re left playing defense.  As we all know, it’s hard (but not impossible) to win if you play all defense and no offense!

Cutting inserts types

Insert selection on a lot of shop floors is often done without considering the cutting edge. Would we cut or a log of wood with a kitchen knife, or a tomato with an axe ?

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Insert geometrychart

Here the nungu was cut into pieces, served with the Neera in the leaf of the tree. Usually the fruit and the Neera are had separately. Vast improvement over serving the Neera in boring and eco-unfriendly plastic glasses.

Carbideinserttypes

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So my question is, why don’t people emphasize material removal rate more so you can know all the parameters you need to define a cut?

Nungu is the fruit of the Toddy palm tree, and Neera is the juice that is collected by tapping new shoots. Neera is sweet when freshly tapped, ferments and becomes the sour alcoholic drink Toddy by evening.

Milling inserttypes

I had ‘Nungu’ (called Tari in Hindi) in Coimbatore. I’ve eaten it numerous times before, but never this way, with such nice aesthetics.

Pretty easy to understand, right?  And doesn’t it make sense you want the best Material Removal Rate (MRR) you can get?  That will make the job run faster which translates almost 100% into profit or at least time saved if it isn’t a paying job.

I’ve got a question I was hoping you could answer.  It seems like a lot of emphasis is put on calculating feeds and speeds based on chip load.  I understand how that could be a metric, but feeds and speeds only gets you part of the information you need.  When defining a cut, I also need depth of cut and step over.  When I think about those two other variables, it makes me think of material removal rate.

The truth is, most (OK, honestly, EVERY one but CNCCookbook’s G-Wizard Calculator) treatments of feeds and speeds give no help whatsoever for Cut Depth and Stepover (Cut Width).  Folks figure those values out largely by rules of thumb.  It’s how they’ve always worked, and if you follow conventional feeds and speeds approaches to go from your