Page 609 - Master Catalog 2017, Inch

Separator
™
Technical Recommendations • Separator Cut-Off System

Improve chip control: Figure A
• Adjust feed rate up or down to accommodate chip formation.
• Use a 0° or smallest lead available.
• Use ample amounts of well-directed coolant (see Figure A).
• Maintain sharp cutting edge and corners.

Coolant on cut-off tool Preferred method of applying coolant

Improve fl atness of cut-off surfaces:
• Maintain 90° position (perpendicular alignment) between
cut-off tool and workpiece.
Figure B
• For low to moderate speed (sfpm), use Separator F 2 .
• For moderate to high speed (sfpm), use Separator S 2
or X 2 .
• Use strongest toolholder system possible.
• Use 0° lead angle inserts when possible. If lead angle
inserts are needed, reduce the feed rate.
• Check for minimum overhang of holder and blade.
• Set up for minimum workpiece overhang
(distance out of chuck).
Minimize edge chipping:
• Reduce feed rate.
• Check to see if tool is signifi cantly above or below center.
• Maintain sharp edge and corners on cut-off insert.
• Reduce feed prior to part drop-off.
• Increase speed (RPM).
• Use Separator S 2 or X 2 .
• Use ample amounts of well-directed coolant
(see Figure A). • Choose the proper speed associated with the insert
grade used.
• Maintain proper tool center height .000–.005"
(0–0,1mm) above center (see Figure B). • Call Technical Support to see if a larger hone size
is needed.
• Eliminate chatter.
• Avoid chip re-cutting.
• Check for these part and machine problems:
– Slide is loose.
– Slide travel is irregular.
– Bar/tube I.D. and/or O.D. is out of round.
– Bar/tube is bent.
Improve surface fi nish: – Thin wall collapses (deforms) in the cut.
• For low to moderate speed (sfpm), use Separator F 2 . – Part is unstable.
• For moderate to high speed (sfpm), use Separator S 2 or X 2 . – Cut-off through unturned stock.
• Avoid overly aggressive chip control. – Excessive tool overhang.
• Increase speed. – Bent or partly attached fl ash ring.
• Reduce lead angle and feed rate.
• Determine if corner radius is too large or small.
• Use a coated grade.
• Use coolant (see Figure A).

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