Torque/HP and tool wear/breaking

cncmach7050 · Jan 26, 2020

Quick recap: The shop where I work has been running Fadal's exclusively for 25+ years, until two years ago when they purchased a new Hurco. The owner and programmer have spent a total of less than 40 hours on this machine and have left it to me to learn everything. (This can be a lot of fun, but also very frustrating!)
So, when I am cutting steel I see tool wear/breakage and parts lifting in the vice that didn't occur on the Fadals. When I ask for help, they just tell me it is the way they have always run these parts and they have never had trouble before.
Do I need to adjust RPM/SFPM when cutting steel on the Hurco to compensate for it being more powerful machine (torque/HP) than the Fadals?

Ianagos · Jan 26, 2020

If it’s the same tools and same vices along with same feeds and speeds it should work just fine. You can have 10 or 50hp at the machine if you are using the same feeds and speeds it will be the same power used.

Now what is probably happening is you are using faster speeds and feeds therefore pulling the parts out. Is that the case?

cncmach7050 · Jan 26, 2020

Ianagos said:
If it’s the same tools and same vices along with same feeds and speeds it should work just fine. You can have 10 or 50hp at the machine if you are using the same feeds and speeds it will be the same power used.

Now what is probably happening is you are using faster speeds and feeds therefore pulling the parts out. Is that the case?

I am using the same programs--only changing E1's to G54's and putting a G28 at end of tools/program. Speeds and Feeds are the same. This is why I am digging deeper...

Cole2534 · Jan 26, 2020

I see a couple possibilities:

Workholding- is everything locked down solid? You don't directly state if you ever ran the Fadals so we're not sure of what you're used to.

Improper feed mechanisms on the Hurco- How is the backlash on the hurco? Excessive amounts can lead to erratic feeding and that may exhibit itself as you've described. This could be expanded to loose gibs or poorly tuned servos as well.

Coding errors- If you're only changing offsets and some other minor code it makes me wonder if the Hurco needs different G code beyond the obvious.

cncmach7050 · Jan 26, 2020

I should have made it clear--I was running (and still do sometimes) the Fadals before we got the Hurco. According to what I've read G01/02/03 are the same for Fadals and Hurco. I will look into the backlash issue.

DouglasJRizzo · Jan 26, 2020

It sounds like the D.O.C. on the Hurco is greater than the other machines. This will definitely cause lifting of the part. The difference is that the Hurco won't stall.

JS · Jan 26, 2020

Cole2534 · Jan 26, 2020

cncmach7050 said:
I should have made it clear--I was running (and still do sometimes) the Fadals before we got the Hurco. According to what I've read G01/02/03 are the same for Fadals and Hurco. I will look into the backlash issue.

Probably. I was thinking more about things like G8/G9.

Ianagos · Jan 26, 2020

Cole2534 said:
Probably. I was thinking more about things like G8/G9.

That’s a good point suggestion. The hurco may handle the tool path slightly different pushing the part into the corners faster.
May have faster accelerations and faster processing speed making the actual feed faster.

cncmach7050 · Jan 26, 2020

Ah. This is good info. I will look in the morning. Thank you.

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