1 Bluewater Wood Alliance – September 30, 2011 Aerotech System Spiral Router Bit Selection, Operation & Service Dean Garbett Frank Horvath

2 Bluewater Wood Alliance – September 30, 2011 Tt

3 Bluewater Wood Alliance – September 30, 2011 The Aerotech System provides near or complete extraction of dust and debris while cutting. When the Aerotech System is used in conjunction with an Aerotech Ready CNC machine; the performance is guaranteed and your plant will receive immediate increases in production throughput and operating environment benefits. - less dust + much healthier = more savings

4 Bluewater Wood Alliance – September 30, 2011 Cutting Tool Improvements ･ Extended tool life ･ Single pass, finished cuts ･ Lower operating temperatures Production Improvements ･ Higher production throughput ･ No or little post-cycle cleanup Sustainable Environmental Improvements ･ Dramatically improves workplace environment ･ Supports environmental management programs ･ Lowers energy usage from decreased compressed air usage ･ Reduced levels of hazardous airborne particulates

5 Bluewater Wood Alliance – September 30, 2011 Spiral Router Bits

6 Bluewater Wood Alliance – September 30, /3 decrease of nesting cycle time = 24 hours per month of additional production Increased Throughput Sample ProductionBusiness 5 minute setup8 hour shift 10 minute nesting cycle5 day work week 5 minute clean up4 weeks per month

7 Bluewater Wood Alliance – September 30, 2011 General Design Influence of Sharpening Understanding the act of cutting How to choose your spirals Explore Optimizations New Developments

8 Bluewater Wood Alliance – September 30, 2011 General Design

9 Bluewater Wood Alliance – September 30, 2011 Primary Secondary Third, etc… Flute Rake Back Relief Design Characteristics Hook Angle Clearances Flute Affects of sharpening

10 Bluewater Wood Alliance – September 30, 2011 New Tool Geometry

11 Bluewater Wood Alliance – September 30, 2011 New Tool Geometry Notice the change in rake angle with each sharpening

12 Bluewater Wood Alliance – September 30, Sharpening Notice the change in rake angle with each sharpening The min. core diameter may be Reduced with each sharpening

13 Bluewater Wood Alliance – September 30, 2011 Replace Tool Changing Tool Dimensions Based on a 1/2” Diameter, 2+2 Compression with Standard Cutting Features * Flute depth is maintain if “Re- Fluting” service is provided

14 Bluewater Wood Alliance – September 30, 2011 Understanding the act of cutting

15 Bluewater Wood Alliance – September 30, 2011 What is Ramping? Straight PlungeRamping Plunge

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21 Bluewater Wood Alliance – September 30, 2011 How to choose your spirals –What level of surface finish do you require? –What is the maximum Depth of Cut, Cutting Diameter and Material Hardness? –What is the required Surface Finish, Shape of the Cutting Path and available Feedrate/RPM? –What type of Surface Finish is required at the bottom of the cutting path and is it Flat?

22 Bluewater Wood Alliance – September 30, 2011 Finishing Cutting Edge Consistent smooth finish Will produce a large chip Will produce more heat and more cutting pressure than modified cutting edges such as Rougher or Chipbreaker designs

23 Bluewater Wood Alliance – September 30, 2011 Chipbreaker Cutting Edge Cutting edge contains 1/16” serrations in the cutting edge –May prevent tear-out from the core material, such as in plywood or foam core. –Smaller chip sizes during cutting operations and after re-cutting of chips occurs –Reduced noise level due to staggered cutting edges Will likely produce a cut that contains some fuzzing along the core material face.

24 Bluewater Wood Alliance – September 30, 2011 Roughing Cutting Edge Cutting edge contains “Knuckles” –Reduced cutting pressure allowing for significantly higher feed-rates in hard materials –Smaller chip sizes created during cutting operations –Reduced noise level due to staggered cutting edges Will produce a cut that is slightly uneven along the core material face

25 Bluewater Wood Alliance – September 30, 2011 Standard Helix Angle, 30 degrees Provides an aggressive cutting edge that delivers more cutting pressure, easily severing wood fibres and brittle laminated faces. It is important to understand that it is not only the rake angle that produces cutting pressure but also the helix angle. Together these features determine how fibrous materials are cut.

26 Bluewater Wood Alliance – September 30, 2011 Low Helix Angle, 10 degrees Produces significantly less lateral pressure on the cutting tool that improving rigidity, allowing for longer flute lengths when cutting hard materials and reduce tool run-out Lower operating noise levels May increase cutting edge life in hard materials as a result of the lower required cutting pressure applied to the cutting edge

27 Bluewater Wood Alliance – September 30, 2011 What Helix Angle is required? –30 Degrees –10 Degrees –Straight

28 Bluewater Wood Alliance – September 30, 2011 What type of Surface Finish is required? –Finishing –Chipbreaker –Rougher

29 Bluewater Wood Alliance – September 30, 2011 Which Direction should the cutting pressure be exerted? –Upcut –Downcut –Compression

30 Bluewater Wood Alliance – September 30, 2011 What is the maximum Depth of Cut, Cutting Diameter and Material Hardness? –Single diameter –Lock-Mortise –Tapered

31 Bluewater Wood Alliance – September 30, 2011 What is the required Surface Finish, Shape of the Cutting Path and available Feedrate/RPM? –Single Flute –Two Flute –Three Flute

32 Bluewater Wood Alliance – September 30, 2011 What type of Surface Finish is required at the bottom of the cutting path and is it Flat? –Gashed –Near Flush –Flush –Ballnose –V Point

33 Bluewater Wood Alliance – September 30, 2011 Explore Optimizations

34 Bluewater Wood Alliance – September 30, 2011 Optimizing your spirals –Achieve perfect cut quality –Longest tool life –Maximize number of sharpenings

35 Bluewater Wood Alliance – September 30, 2011 Feed Rate & RPM –Material to be cut –Depth of cut Cutting pressure & potential run-out –Number of cutting edges Size of Flute –Outside Diameter (OD) clearances Number of sharpenings –Prevent Heeling throughout service cycles with minimal operator input

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37 Bluewater Wood Alliance – September 30, 2011 Oscillating or Z axis Offset –Is the vertical movement of the cutting tool –The objective is to change the point of contact and thereby increased the number of cuts a tool can make before an unusable wear point is created –Effective when cutting melamine, veneered or other faced materials