Cycle time isn’t always the best way to assess to the overall profitability of your workflow. The choices you make in tooling and programming can make follow-up operations easier, help eliminate costly recutting and reap the benefits of more usable insert edges. In this video, we examine why a button cutter might actually be a great choice for high-feed mold core ramping and compare options for finishing the part, comparing bull nose to ball nose cutters and waterline profiling to plunge finishing.
As you can see, mold core roughing can be very effectively done using high-feed ramping – even with a button cutter! Our EDGE² DTB series double-sided button cutters are robust, 12-index tools that allow for aggressive metal removal.
Though the cycle time with your button tool may be a bit slower than it would be with high-feed tooling, economically speaking you can make a strong argument for it being a great choice for this type of application:
Mold core finishing can be done with any number of different cutter styles. As this video shows, one of the most efficient methods is to use a smaller-radius bull nose-style tool – but using a plunge finishing approach vs. traditional waterline profiling. Our EDGE² SBN system with SBD back draft-style inserts is a great choice for this type of application.
Ball nose and barrel-style cutters can take a large step down, but they also create more tool pressure due the increase in surface-area contact. This can cost you in terms of both finished part size and time due to the a need for subsequent additional finish passes. Though it may be a few minutes slower than the ball nose tool, in this instance plunge finishing with a bull nose-style tool:
Our applications specialists are always available to help you choose the best tooling and processes to maximize your shop's profitability.
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