Accuromm Central Europe
/ A tool engineering company that supports all work related to tools
Accuromm Central Europe
A tool engineering company that supports all work related to tools
Predictible engineered micro-geometries (EMG)
Scientifically proven and patented process
Proper edge prep adds strength to the cutting edge, dramatically increasing the usable lifespan of the tool.
Eliminates microscopic defects and strengthens the edge, leading to more predictable performance from tool to tool.
Minimizes the tendency of the tool edge to chip, resulting in improved workpiece surface finish and dimensional consistency.
Reduces the chance for catastrophic tool failure and chipping, especially when machining exotic or high-performance materials in untended CNC environments.
Proper selection and application of cutting tool edge preparation is one of the basic ingredients for a successfully manufactured and optimum performing cutting tool.
Edge defects are present in nearly all tools prior to edge prep. The defects are the result of die flash after pressing, EDM processing and grinding. Although microscopic in size, such defects will lead to erratic tool performance and premature tool failure.
The tool edge preparation process, when administered properly, adds strength to the tool cutting edge, lengthens usable tool life, minimizes the propensity of the edge to chip, improves part quality and consistency, and enhances work piece surface finish. Some of the edge preparation options currently used by the tool manufacturers:
The most widely used edge preparation that exists in industry today is the radius and waterfall hone shapes. These edge preps are applied in a variety of sizes based on cutting tool size and application. Edge prep is not limited to application of indexable style tooling. It is required on most cemented carbide round tools, brazed steel shank tools, PCD and PCBN tools, and single/multiple edge cemented carbide form tools. While T-Lands (or K-Lands) are ground on to the tool edge, edge hones are applied to cutting tools in a variety of methods. These processes include vibratory honing, honing by hand with diamond stones, mass media honing, slurry honing, honing inserts with media impregnated rubber wheels, dry blasting, wet blasting, tumbling and brush honing with abrasive media impregnated filaments.
Today the process of cutting tool edge honing still remains an art for most tool manufacturers. The conventional honing processes available today are highly prone to over-working the corners of the tool and they can be difficult to control tool-to-tool because incoming part condition can vary. The honing process is still guided by the best educated guess scenario limited by machine variability and operator expertise.
With Conicity Technologies this all changes, making it a science. Now the technology and equipment exists using the nylon abrasive filament brush technique to overcome nearly all the current processing problems and to produce a tool that will yield optimum performance in any given operation or application. The following pictures illustrate just a few of the tool types to which Conicity can apply the EMG™ edge prep.
What tools can benefit from edge preparation:
Try our edge preparation service today!
| Workpiece | Automotive / Cylinder head |
|---|---|
| Application | Face milling |
| Material | Cast aluminium |
| Tool | PCD milling cutter 10″ (254mm) 30z |
| Criteria | Burr generation |
| Before | Lifetime: 65,000 pcs |
| After | Lifetime: 275,000 pcs (+423%) with variable edge preparation |
| Reference | Effects of Engineered Micro-Geometry on burr formation in PCD milling of aluminium |
| Workpiece | Medical / Contact lens, intraocular lens (IOL), cataract implant |
|---|---|
| Application | Turning |
| Material | Acrylic (PMMA) |
| Tool | Single crystal natural diamond |
| Criteria | Surface finish |
| After | Tool chipping resistance +200% |
| Workpiece | Automotive & Aerospace / |
|---|---|
| Application | Outside diameter turning |
| Material | SiCp/Al metal matrix composite (MMC) |
| Tool | High-pressure, high-temperature (HPHT) and chemical vapor deposited (CVD) single crystal diamond tools |
| Criteria | Surface finish |
| After | Tool lifetime (CVD) +75% of natural diamond |
| Reference | Performance of single crystal diamond tools in metal matrix composite machining |
| Workpiece | Agricultural, Construction, Mining / Stellite rings |
|---|---|
| Application | Turning |
| Material | Stellite (wear resistant Fe alloy) |
| Tool | CBN insert |
| Criteria | Surface finish |
| Before | CBN insert with standard .005″ x 20° T-land chamfer edge preparation. Failure by massive chipping, not repairable by regrinding. |
| After | CBN insert with waterfall edge preparation shows only abrasive wear and can be reground multiple times. |
| Reference |
| Workpiece | Test bar |
|---|---|
| Application | Dry hard turning |
| Material | W300 (1.2343) 54HRc |
| Tool | CBN insert E6 DCN450 grade Vc=150 m/min, f=0.10 mm/rev, ap=0.1 mm, no coolant (DRY) Tool holder DCLNL 2525 M12 |
| Criteria | Wear and chip control |
| Before | CBN insert with standard T-land chamfer edge preparation: Wear starts from the edge moving inwards. |
| After | CBN insert with waterfall edge preparation: crater wear starts behind and towards the edge. |
| Workpiece | Automotive / Ring and pinion gears |
|---|---|
| Application | Dry gear machining |
| Material | High-strength alloy steel |
| Tool | Carbide gear blade |
| Before | Tool replacement 1,250 times per year, taking 40 minutes each. High non-productive machine time resulting 0.6-1M USD/year losses. |
| After | With edge preparation: Tool life +50% Machining speeds +30% Production capacity +66% |
| Reference | American Machinist – Edge Prep Boosts Tool Life |
| Workpiece | Personal safety device |
|---|---|
| Application | Milling |
| Material | Forged stainless steel |
| Tool | 5 flute variable (unequal) flute spacing carbide endmill |
| Before | Tool chatter, post operation required hand finishing by 17 people |
| After | With edge preparation: Chatter and therefore hand finishing completely eliminated. |
| Workpiece | Automotive / Crankshaft and connecting rod bolt caps |
|---|---|
| Application | Drilling |
| Material | Powder metal forged steel |
| Tool | Carbide drill |
| Before | Severe drill breaks (10-12 pcs/day) |
| After | With edge preparation: |
| Reference | Cutting Tool Engineering – A better edge |
| Workpiece | Hydraulic / Fluid system component |
|---|---|
| Application | Reaming |
| Material | 300 series stainless steel |
| Tool | Carbide drills and reamers |
| Before | Tool chatter |
| After | With edge preparation: |
| Workpiece | Aerospace / Helicopter rotor |
|---|---|
| Application | Drilling |
| Material | Inconel 718 |
| Tool | Carbide drill |
| Before | Lifetime 30 holes |
| After | With edge preparation:
With double feed and speed, penetration rate increased 4x, lifetime 120 holes, while standard deviation for hole size reduced by 66% |
| Reference | American Machinist – Get an edge on tool performance |
| Workpiece | Medical / Artificial hip joints |
|---|---|
| Application | Thread milling |
| Material | Titanium alloys |
| Tool | Carbide thread mill |
| Before | Lifetime: 75 holes High cost of scrap during tool set-up |
| After | With edge preparation: Lifetime: 250 holes. 75% of set-up scrap eliminated |
| Reference | American Machinist – Get an edge on tool performance |
| Model | DXM100 |
|---|---|
| Description | Compact sized edge prep machine |
| Target tool | Drill, reamer, gundrill, trepan, gear stick |
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| Model | EXM100 |
|---|---|
| Description | Compact sized endmill edge prep machine |
| Tool | Endmill, thread mill, tap, step drill |
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| Model | IXM50 |
|---|---|
| Description | Compact sized insert cutting tool edge prep machine |
| Tool | Cutting inserts made of carbide, HSS, Cermet, PCD |
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