WAM and WAMR Tools are Designed for HEM Techniques
Conventional Tool Path
HEM Tool Path
High Efficient Milling (sometimes referred to as High-Efficiency Machining or HEM) tool pathing strategies offer dramatic
improvements in Material Removal Rates (MRR). They also can
reduce roughing cycle times by as much as 70% over traditional
roughing tool paths.
Using WAM and WAMR tools with these HEM roughing tool path
strategies will significantly reduce cycle time. Tool life will increase
by several times due to low stress on the tool.
The HEM tool path is a sophisticated algorithm that is designed
to maintain a constant tool radial engagement with the material.
This constant radial engagement prevents the tool from becoming
overloaded in transitional moments such pushing the tool into
a corner. In a conventional tool path, these transitional moments
can severely overload the tool. These moments cause premature
wear and tool failure.
WAM and WAMR tool operation parameters can be adjusted to
take advantage of the constant loads that HEM techniques offer.
Deep Axial Depths: WAM and WAMR can be programmed for up to 4X diameters DOC. This means that
it can do deep cavity or contour tool paths in one pass. It only needs to go through the tool path once at
depth and not stepping down for each pass.
Light Radial Engagement: On deep axial depths, a light radial engagement evens out the pressure and
wear over the entire tool. This helps to increase tool life. Typically, light radial engagements are from 5 to
12% of the tool diameter.
Heavy Radial Engagement with HEM: WAM and WAMR tools have deep chip gullets designed for
chip evacuation. In shallow depths, the radial engagement can be increased to 33% or more of the tool
diameter. This vastly improves MRR in these shallower depths. The secret to high radial engagement
success is in the constant radial load of the HEM tool path.
Higher Spindle Speeds: Because the end mill is only engaged with the material for a small percentage
of the spindle rotation, the spindle rpm is increased. This will maintain the necessary heat for proper chip
plasticization and preventing built up edge.
Higher Feed Rates: The light radial engagement allows the use of chip thinning calculations to help
maintain the correct chip load. Typically, a radial engagement of 7% of tool diameter will allow for a
doubling of the normal feed rate used for slotting. Feed rates can be higher in good stable conditions.
Combining WAM and WAMR tools with HEM programming techniques is a winning strategy for reducing cycle
time, improving tool life and improving profitability. HEM programming techniques have a clear advantage over
traditional tool paths by increasing MRR to the highest degree possible with today's modern CNC machine tool.
WAM Features & Benefits
Optimized flute geometry provides excellent chip evacuation for high efficiency machining and traditional tool paths
Available in square, corner radius and ball nose
Wiper flat provides superior floor finish
Extra fine grain carbide with high transverse rupture strength for higher feed rates
Chipbreaker flute design allows for increased cutting speeds and material removal rates
Smaller chip creation during machining eliminates long stringy chips
Each rougher is coated with extremely low friction ONX coating
WAMR Diverse Machining Techniques
Deep HEM Pocketing
Light and Heavy HEM Contouring
Programmer's Perspective on WAMR
One of the unintended consequences of 2 to 4 times diameter deep axial High Efficient Milling (HEM)
is the creation of "long, stringy chips." These chips do not flush away easily and tend to remain on
the work holding and machine tables requiring machine operators to expend extra time clearing
them during part change outs.
An aerospace facility that aggressively uses HEM roughing tool path strategies was experiencing
this issue on their vertical milling machines and the time saved from HEM milling was being lost
clearing matted together chip piles on the work holding and machine table.
This shop was introduced to the WAM Rougher to help increase their metal removal rates, while
also eliminating these longer chips. The WAM Rougher is designed to take aggressive feed rates,
while also breaking up the chips into shorter segments that can be easily flushed away from the
part. The coolant stream carries them to the chip conveyer for quick removal.
The WAM Rougher proved to be a great solution. By design, the WAM Rougher allows light duty
vertical and horizontal mills to be more efficient at aggressively cutting material, while solving the
chip evacuation and piling problems.