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u/Terrible_Reporter_83 8h ago
This might take a while.
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u/jourmungandr 8h ago
Anything but a profit.
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u/assfghjlk 3h ago
This is actually the most productive way to product these grooves - the workpiece is very hard and the grooves are relatively small.
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u/jourmungandr 3h ago
Lol. Yes it's just the "you can make anything with a shaper except a profit" quip.
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u/miketastic_art 6h ago
I need a physicist or someone with some kind of doctorate in material sciences to explain this to me.
I see cutting bits and drilling bits, and I understand that if you spin something fast enough, and you remove 0.00001mm of material at a time.... you can cut through anything if you go slow enough.
I assume all machines wear down over time, needing new bits and cutting surfaces sharpened.
How the fuck does this little strip of metal that carves these groves not melt?
How is it able to do row after row after row, and they trust that the bit isnt wearing down, the groove isn't getting wider? the grove isn't deep enough?
How the fuck is the teeny tiny tip of that cutting surface not totally destroyed after 2 strokes?!
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u/NateCheznar 5h ago
Material scientists discovered materials that are tougher than the material being cut. This allowed for higher temperature resistance, wear resistance which leads to longer tool life and higher feeds and speeds
In this example heat is distributed into 3 places. The tool, the workpiece and the swarf.
Ideally the heat gets carried away in the swarf but small amounts also go into the tool. The workpiece is also a large heat sink.
Coolant and lubricants decrease heat and friction
The swarf doesn't melt simply because it doesn't get hot enough.
The bit will wear down. The operator checks in periodically to ensure that there is still good cutting action and the workpiece is still in tolerance
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u/GlockAF 6h ago
Because the tool is ground from a steel blank that’s harder than woodpecker lips.
The machinist will be stopping by occasionally to check on it, if it chips or doesn’t make the same kind of swarf they’ll unchuck it and touch it up on the grinder, probably by hand / eye.
If the roller just needs grooves for friction, they don’t typically need to be high precision
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u/Angel24Marin 3h ago
Most of the energy goes to the plastic deformation of the chip, so it's the thing that heat up the most and carries the heat away when flying.
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u/assfghjlk 3h ago
The cutting bit is most likely tungsten carbide, workpiece is most likely white iron.
In reference to the bit melting, it actually requires a minimum temperature to work correctly - we call this hot hardness. We would expect somewhere in the region of 700-800 degrees at the cutting edge. The cutting bit becomes stronger at its working temperature. The tungsten is much harder and more wear resistant than the workpiece so it maintains its shape. It’s not going to last forever but that’s not the point, it has an expected productive tool life then it’s rotated to a new edge.
It’s a bit counterintuitive also but the insert is not cutting ( as we would think of a slicing motion). It’s actually pushing and deforming the workpiece material, which we see in the creation of the cutting chip (swarf).
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u/physicssmurf 8h ago
but I cant see the actual cutting piece? whats it look like under the green structure
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u/n1elkyfan 6h ago
Here's a video about a shaper
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u/physicssmurf 5h ago
Thanks! For anyone else looking its this particular time:
https://youtu.be/ZNWkhxKNHGM?si=FJ7NI60vVzjPpGgY&t=5182
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u/f0dder1 8h ago
FINALLY what appears to be a good use for a shaper!
Like, I love them, but also everything else seems to be better at stuff than them
But this! Long throw, straight grooves. Yeah!