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Milling For Smoothness
Continuous Milling
There are a lot of forces
generated during milling.
When you stop so do the
forces.
Plus all of the tee...
Importance of the Water System
Too much water presents problems:
Water costs money.
Excessive water makes the water truck ...
RX-900
A
M
AUTO
2D Control Systems
AUTO
A
M
AUTO
V
L R
M
A
RX-900
AUTO
A
M
AUTO
V
L R
M
A
Averaging Systems
A
M
AUTO
3D Control Systems
Mill to Grade based on Position
Proper Maintenance
Proper Maintenance
Proper Holder Wear
Tool Wear Characteristics
At Stage 3
Tool has lost 0.365 “ [9.3 mm] of
gage height
0.43 in20.15 in2 287% Increase in Surfa...
Production Tradeoff
0
20
40
60
80
100
120
140
160
180
0 2 4 6 8 10 12 14
AdvanceRate(fpm)
Milling Depth (inch)
RX-900 New ...
0
20
40
60
80
100
120
140
160
180
0 2 4 6 8 10 12 14
AdvanceRate(mpmorfpm)
Milling Depth (cm or inch)
RX-900 New Teeth
RX-...
Look at the Holders
Caliper set at EXACTLY 2”
The tooth tip should
be centered on the
blue line.
The red line shows the
misalignment of the tooling
due to the face wear...
Novatec Diamond, Kenamental
•
Both fit into a
Kenametal quick
change holder
Both are the same
height
Tooth Pattern
Keep it Clean
Your Cut surface is only as good the
surface you Walked on.
If you have this to work with you will
never ach...
Clean up your mess
Our shovel is on the water truck.
The automatics will take that out…
The Math of Milling
Drum RPM
Forward
Speed
Line Spacing
0
Lacing Pattern
Diameter
The 4 Main Factors that
Affect Surface T...
Line Spacing and Texture
5/8” (16mm) Triple Wrap Lacing
Pattern
5/8” 5/8”
≈⅛”
5/8” (16mm) Triple Wrap Lacing
Pattern
5/8” (16 mm) Triple Wrap at 30 fpm
2/10” (5mm) Triple Wrap Lacing
Pattern
0.2”
≈1/16”
2/10” (5mm) Triple Wrap Lacing
Pattern
2/10” (5mm) Triple Wrap Lacing
Pattern
Amount of Tools
12’6” (3.5 m) Full Lane Drum
Line Spacing # of Teeth Cost of Teeth
5/8” (16 mm) 268 $1340
3/8” (9 mm) 406 ...
Production Tradeoff
0
20
40
60
80
100
120
0 2 4 6 8 10 12 14
AdvanceRate(fpm)
Milling Depth (inch)
RX-900 12'6"
Production Tradeoff
0
20
40
60
80
100
120
0 2 4 6 8 10 12 14
AdvanceRate(fpm)
Milling Depth (inch)
RX-900 12'6"
RX-900 12'...
The Math of Milling
Drum RPM
Forward
Speed
Line Spacing
0
Lacing Pattern
Diameter
The 4 Main Factors that
Affect Surface T...
Forward Speed
Advance Rate = 30 fpm
Drum Diameter = 46”
Drum Speed = 100 rpm
Advance Rate = 30 fpm
Machine
Advance
3.6”
0.071”
30 fpm
Advance Rate = 60 fpm
Machine
Advance
7.2”
0.28”
Advance Rate = 60 fpm
Drum Diameter = 46”
Drum Speed = 100 rpm
60 fpm
Advance Rate = 120 fpm
Machine
Advance
14.4”
1.16”
Advance Rate = 120 fpm
Drum Diameter = 46”
Drum Speed = 100 rpm
120 fpm
30 fpm vs. 120 fpm
2.3 miles in a day vs. 9.1 miles in a day
The Math of Milling
Drum RPM
Forward
Speed
Line Spacing
0
Lacing Pattern
Diameter
The 4 Main Factors that
Affect Surface T...
Drum Speed
RX-900 Drum Speeds
Engine Speed Top Sheave Bottom Sheave Gear Ratios
Diameter (in) Diameter (in) 20:1 24:1
2100...
The Math of Milling
Drum RPM
Forward
Speed
Line Spacing
0
Lacing Pattern
Diameter
The 4 Main Factors that
Affect Surface T...
Drum Lacings
Scroll Start Comparisons
Triple Wrap Double Hit Quad
Wrap
Double Hit Drums
Above
Double hit Quad wrap drum
Standard triple wrap drum
Below
Pattern Comparison
7/8” DHQW at 100 FPM5/8” Triple Wrap at 100 FPM
Production Tradeoff
0
20
40
60
80
100
120
0 2 4 6 8 10 12 14
AdvanceRate(fpm)
Milling Depth (inch)
RX-900 12'6"
RX-900 12'...
Production Tradeoff
0
20
40
60
80
100
120
0 2 4 6 8 10 12 14
AdvanceRate(fpm)
Milling Depth (inch)
RX-900 12'6"
RX-900 12'...
Thank you & Slow Down
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Jeff Ensell -- Milling & Paving for Smoothness

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Presentation delivered at the CalAPA Spring Asphalt Pavement Conference April 9-10, 2014 in Ontario. Topic: Milling and paving asphalt for smoothness from the perspective of an equipment manufacturer, including best-practices, technology and more.

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Jeff Ensell -- Milling & Paving for Smoothness

  1. 1. Milling For Smoothness
  2. 2. Continuous Milling There are a lot of forces generated during milling. When you stop so do the forces. Plus all of the teeth now cut in one spot, no longer spread out.
  3. 3. Importance of the Water System Too much water presents problems: Water costs money. Excessive water makes the water truck driver have to go and fill up more often and it maybe You.. Inlaying use as little water as you can. Water usages are: dust control, tooth cooling, and tooth rotation. Use only enough to accomplish these 3 things. We have to stop to get the water.
  4. 4. RX-900 A M AUTO 2D Control Systems AUTO A M AUTO V L R M A
  5. 5. RX-900 AUTO A M AUTO V L R M A Averaging Systems A M AUTO
  6. 6. 3D Control Systems Mill to Grade based on Position
  7. 7. Proper Maintenance
  8. 8. Proper Maintenance
  9. 9. Proper Holder Wear
  10. 10. Tool Wear Characteristics At Stage 3 Tool has lost 0.365 “ [9.3 mm] of gage height 0.43 in20.15 in2 287% Increase in Surface Area
  11. 11. Production Tradeoff 0 20 40 60 80 100 120 140 160 180 0 2 4 6 8 10 12 14 AdvanceRate(fpm) Milling Depth (inch) RX-900 New Teeth
  12. 12. 0 20 40 60 80 100 120 140 160 180 0 2 4 6 8 10 12 14 AdvanceRate(mpmorfpm) Milling Depth (cm or inch) RX-900 New Teeth RX-900 Stage 4 Teeth Wear Production Tradeoff
  13. 13. Look at the Holders Caliper set at EXACTLY 2”
  14. 14. The tooth tip should be centered on the blue line. The red line shows the misalignment of the tooling due to the face wear on the tooth holder.
  15. 15. Novatec Diamond, Kenamental • Both fit into a Kenametal quick change holder Both are the same height
  16. 16. Tooth Pattern
  17. 17. Keep it Clean Your Cut surface is only as good the surface you Walked on. If you have this to work with you will never achieve grade. Why?
  18. 18. Clean up your mess Our shovel is on the water truck. The automatics will take that out…
  19. 19. The Math of Milling Drum RPM Forward Speed Line Spacing 0 Lacing Pattern Diameter The 4 Main Factors that Affect Surface Texture 1. Line Spacing 2. Forward Speed 3. Drum RPM 4. Lacing Pattern
  20. 20. Line Spacing and Texture
  21. 21. 5/8” (16mm) Triple Wrap Lacing Pattern
  22. 22. 5/8” 5/8” ≈⅛” 5/8” (16mm) Triple Wrap Lacing Pattern
  23. 23. 5/8” (16 mm) Triple Wrap at 30 fpm
  24. 24. 2/10” (5mm) Triple Wrap Lacing Pattern
  25. 25. 0.2” ≈1/16” 2/10” (5mm) Triple Wrap Lacing Pattern
  26. 26. 2/10” (5mm) Triple Wrap Lacing Pattern
  27. 27. Amount of Tools 12’6” (3.5 m) Full Lane Drum Line Spacing # of Teeth Cost of Teeth 5/8” (16 mm) 268 $1340 3/8” (9 mm) 406 $2030 0.2” (5 mm) 770 $3850 Nearly 3 times more teeth Nearly 5 times the cost No more quick change holders
  28. 28. Production Tradeoff 0 20 40 60 80 100 120 0 2 4 6 8 10 12 14 AdvanceRate(fpm) Milling Depth (inch) RX-900 12'6"
  29. 29. Production Tradeoff 0 20 40 60 80 100 120 0 2 4 6 8 10 12 14 AdvanceRate(fpm) Milling Depth (inch) RX-900 12'6" RX-900 12'6" Micro
  30. 30. The Math of Milling Drum RPM Forward Speed Line Spacing 0 Lacing Pattern Diameter The 4 Main Factors that Affect Surface Texture 1. Line Spacing 2. Forward Speed 3. Drum RPM 4. Lacing Pattern
  31. 31. Forward Speed
  32. 32. Advance Rate = 30 fpm Drum Diameter = 46” Drum Speed = 100 rpm Advance Rate = 30 fpm Machine Advance 3.6” 0.071”
  33. 33. 30 fpm
  34. 34. Advance Rate = 60 fpm Machine Advance 7.2” 0.28” Advance Rate = 60 fpm Drum Diameter = 46” Drum Speed = 100 rpm
  35. 35. 60 fpm
  36. 36. Advance Rate = 120 fpm Machine Advance 14.4” 1.16” Advance Rate = 120 fpm Drum Diameter = 46” Drum Speed = 100 rpm
  37. 37. 120 fpm
  38. 38. 30 fpm vs. 120 fpm 2.3 miles in a day vs. 9.1 miles in a day
  39. 39. The Math of Milling Drum RPM Forward Speed Line Spacing 0 Lacing Pattern Diameter The 4 Main Factors that Affect Surface Texture 1. Line Spacing 2. Forward Speed 3. Drum RPM 4. Lacing Pattern
  40. 40. Drum Speed RX-900 Drum Speeds Engine Speed Top Sheave Bottom Sheave Gear Ratios Diameter (in) Diameter (in) 20:1 24:1 2100rpm 16 14 120rpm 100rpm 2100rpm 16 15 112rpm 93rpm 2100rpm 14 15 98rpm 82rpm 2100rpm 14 16 92rpm 77rpm
  41. 41. The Math of Milling Drum RPM Forward Speed Line Spacing 0 Lacing Pattern Diameter The 4 Main Factors that Affect Surface Texture 1. Line Spacing 2. Forward Speed 3. Drum RPM 4. Lacing Pattern
  42. 42. Drum Lacings Scroll Start Comparisons Triple Wrap Double Hit Quad Wrap
  43. 43. Double Hit Drums Above Double hit Quad wrap drum Standard triple wrap drum Below
  44. 44. Pattern Comparison 7/8” DHQW at 100 FPM5/8” Triple Wrap at 100 FPM
  45. 45. Production Tradeoff 0 20 40 60 80 100 120 0 2 4 6 8 10 12 14 AdvanceRate(fpm) Milling Depth (inch) RX-900 12'6" RX-900 12'6" Micro
  46. 46. Production Tradeoff 0 20 40 60 80 100 120 0 2 4 6 8 10 12 14 AdvanceRate(fpm) Milling Depth (inch) RX-900 12'6" RX-900 12'6" Standard DHQW RX-900 12'6" Fine DHQW RX-900 12'6" Micro
  47. 47. Thank you & Slow Down

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