The Step Reduction Milling® (SRM®) process is a new approach to rough machining.
Current Rough Machining
The current rough machining methods use many separate rough machining, "rest material", and rough finish operations. The tools that the machine operators use have gradually smaller sizes. Larger tools are used to remove a large amount of stock.
Smaller tools are used to cut the material that was left in steps that the larger tool did not cut. Smaller tools also cut the areas that the larger tool did not reach.
After a long and difficult process, the part is ready for the final finish operation.
There are problems with these standard methods of rough machining.
More tool changes and setups cause longer machine time.
Small tools require slower feed rates and speed rates to prevent damage to the tools.
Step Reduction Milling
SRM optimizes the tool use in rough machining.
SRM makes the larger tool remove most of the material from the steps it left in its rough cut. The larger tool removes this material at a faster rate than a smaller tool. The smaller tool is better used to cut the stock that the larger tool cannot reach.
The process uses a maximum of eight tools of gradually smaller sizes in a single operation. Each tool does a roughing cycle in Z that leaves steps of material in each increment. These steps are all of equal height to optimize the tool use with the correct constant feed rates and speeds.