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| Frequently Asked Questions |
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| What is Hi-Life? |
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Hi-Life is a portable, completely electronic instrument meant to relieve the residual stresses in the tools. It works on single-phase 230V input. By relieving the residual stresses it results in an increase in the cutting tool life. |
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| What are the main causes of Tools failure? |
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Residual Stresses are one of the major culprits behind tool failure. The stresses are generated during the following stages in the life of a tool and they remain in the tool even after the processes are removed.
- During the manufacturing stage of the tool.
(Initial machining of blanks, Heat Treatment, Final Grinding).
- During various processes like Tin Coating etc.
- During the actual use of the tools for production.
- And especially during regrinding.
All these processes lead to distortion of the crystalline structure and generation of residual stresses. The distorted microstructure consists of minute defects where tiny cracks are initiated. They are nothing but the surface cracks in their infancy. As more stresses generate, the cracks increase in size thus ending tool life. By making the mircostructure, more homogenous (i.e. relieving the residual stresses), Hi-Life reduces the incidence of chipping, cracking and fracturing as well as blunting. |
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| How does Hi-Life work? |
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Hi-Life works on electromagnetic principles. Specifically generated electromagnetic waves using high frequency switching power source penetrate the tools placed in the tool chamber causing molecular vibration on the skin of the tool are more than the vibration at the core. This results in an unequilibirium state, which leads to the generation of shear forces. Also, the molecules in the distorted microstructure get aligned to these magnetic field. The above process is repeated many times in a single second which will result in to permanent changes in the microstructure. The changes include the reorientation of the magnetic domains. Thus, the residual stresses get relieved. All this results in one conclusion. An increased tool life.
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| What Tools can be used in Hi-Life? |
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| All HSS tools (M2, M35, M42 Grades) T42, solid carbide tools, carbide tipped, carbide inserts can be effectively used. The only restriction is that tools should have a maximum diameter of 40 mm and a maximum length of 175 mm. |
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| Can more than one tool be treated at the same time? |
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| Yes, you can relieve as many tools as are possible to fit in the tray provided in a single cycle. |
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| What happens if wrong cycle is selected? |
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| The will be no damage to the tool. The stress relieving cycle will be carried out only partially. After the cycle is over, the correct cycle can be selected. |
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| When should the tools be treated ? |
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There tools can be treated in the new condition itself. There are residual stresses present in the new tool due to the manufacturing process. The tools must be treated after any coating process to relieve the generated stresses. After every regrinding there are a lot of stresses generated. Hence the treatment must be carried out after every regrinding.
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| Will the tool be damaged if treated many times? |
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| There is no damage to the tool. |
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| How much tool life increase can we expect ? |
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The increase in tool life depends on the state of the microstructure at the time of treatment. This microstructure is dependent on many factors including tool material quality of heat treatment, quality of regrinding etc. Hence the increase cannot be constant every time. You can expect an increase anywhere from 25% to 50% and many times going up to 300% also !! |
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| Should the Tool be left in the magnetised or demagnatised condition? |
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Magnetizing will be useful while machining non-ferrous material since it will increase the rigidity of the tool. Otherwise in the ferrous machining, it is better to keep the demagnetized state to prevent the chips from sticking to the tool. |
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| What are its other applications? |
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The instrument can be used for other functions as follows :
- Small metal parts in assemblies can be magnetised before assembly. This will make assembly easier.
- Stress relieving can be done on many other components in any assembly for a longer life.
- Before any resharpening, the tools can be demagnetised. This will improve straightness of cutting tool edges and smoothness of land.
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