How Important is Edge Quality For Accurate Endmill Tensile Specimen Preparation?

2018-08-10 05:40:00
The manner in which a tensile specimen is prepared is of vital importance if accuracy is at all important to you—which, of course, it is.

Even slight deformities in tensile specimen preparation can completely ruin the accuracy of test results.

With this in mind, we'd like to discuss with you the importance of providing your endmill operator with complete and accurate specimen information. Not all endmills are right for the same job—when we receive specimen information, we analyze it to learn which endmills are most ideal for your unique requirements.

Furthermore, the manner in which a specimen is prepared and handled is very important, which we'll also discuss here.

Let's begin by talking about the first stage of tensile sample preparation: the consumables used and why they matter.

Understanding Tensile Sample Preparation Consumables and Edge Quality

At TensileMill CNC Inc., we have our own brand of consumables for tensile specimens. These have been specifically designed and tested for our endmills so that we can provide only the most reliable and accurate specimens with our machines.

The technology behind the preparation of tensile specimens has been greatly advanced and improved upon over the years. In the old days, eccentric presses were used. However, this method would almost always cause what we now consider to be an unacceptable amount of edge damage. Compression, deformation, and hardening would occur, which required further strengthening via cold working.

Cold working, a process that involves mechanical stress in a low temperature environment, produced fairly decent specimens for the time. Unfortunately, permanent defects would be left in the sample as a result of the process—the material would become too brittle, to the point that its yield strength was dramatically reduced, making it unusable in most industries.

Why Use CNC Endmills Instead of Other Solutions?

In modern times, where every bit of accuracy is important for both performance and regulatory compliance, we use high quality CNC endmills like the TensileMill CNC. These machines are the only cost-effective tensile sample preparation solutions which don't result in specimen deformation or damage unlike cold work machines, laser cutters, or plasma cutters.

CNC tensile sample preparation endmills transfer only a small amount of heat to the sample and utilizes a machine coolant for lubrication and temperature regulation. Just as endmill technology has advanced, so too have consumables. Precision CNC endmills can work with metals, plastics, laminates, acrylics, and composites.

Furthermore, these accurate CNC endmills will help your organization adhere to whatever industry standard you use. That includes the ASTM, ISO, JIS, DIN, or others—truly a modern day solution for increasingly international and diverse industries.

The Effects of Flute Count and Ferrous Material Tooling

Another very important consideration when selecting tensile specimen preparation endmills is flute count and the tool material, such as ferrous or non-ferrous tooling.

Here's what you need to know: tools with more flutes (e.g., 5-8 flutes) will have a larger core and thus more strength. Tools with less flutes (e.g., 3 flutes) will have less strength and larger flute valleys.

CNC endmills with more flutes have become the industry standard, usually ranging between 5-7 flutes but sometimes more. They are also generally made of a ferrous material, leading longer lifespans, additional durability, and an overall higher MRR not to mention operator productivity benefits.

Why Accuracy & Precision is so Important for Tensile Sample Preparation

For many industries, reliable, accurate, and repeatable tensile testing is of the utmost importance for both product performance and end-user safety.

The most common way for tensile tests to become corrupted is through improper specimen preparation or handling. If a sample passes a test it should have failed, the results could be disastrous. Additionally, poor sample preparation can at the very least become costly when specimens end up failing tests it should, in actuality, have passed, as the user will have to test another specimen again unnecessarily.

Therefore, accuracy in testing is incredibly important. How the specimen is cut (e.g., nicks, indentations, or jagged edges) can negatively impact tensile strength and dramatically reduce test consistency. Using the right tensile specimen preparation consumables and CNC mill can reduce or eliminate these problems.

Outside of the machine process, operators must also be trained to handle specimens with the utmost care. A sample which has been dropped or mishandled won't be able to provide consistent test results.

To get a consistent, accurate cut, the right kind of endmill must be used in combination with proper handling of the specimen. Let's take a look at some of the different endmill types and in what situations they should be used.

Understanding The Key Characteristics of Endmill Types

As you learned in the beginning of this piece, not all endmills are made the same. Your usage scenario and requirements will impact which endmill type is most ideal for your needs. Some are complex and require a great deal of operator training; others are more user-friendly and require minimal or no training for operators, such as the TensileMill CNC thanks to its powerful-yet-intuitive Carbon software.

Some organizations have found the TensileMill CNC MINI to not only be a perfectly adequate solution, but in many cases a better solution. A small CNC mill offers many benefits ranging from a lightweight form factor to a reduced energy footprint while still offering the full range of capabilities found in a larger machine. The TensileMill CNC MINI also supports the industry renowned Carbon software as well.

Learn More About Preparing Tensile Specimens the Right Way

When working with materials that need to be tested in a highly precise manner, it's easy to understand why using the right tools to do so is incredibly important. That's why NextGen makes it a top priority to provide our clients with only the best endmill products and tensile specimen testing solutions alongside our world-class customer service.

We understand that no two organizations have the same needs. If you choose to work with NextGen, our first goal will be to understand your unique specimen information and requirements so that we can help you discover the solutions you need—there is no "one size fits all" here.

Our team of experts can be reached at 1 (877) 672-2622 or you can request a free quote here.
Contact us today to request a quote for your tensile sample preparation equipment