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Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
Jeff Ensell -- Milling & Paving for Smoothness
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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, …

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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Transcript

  • 1. Milling For Smoothness
  • 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. 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. RX-900 A M AUTO 2D Control Systems AUTO A M AUTO V L R M A
  • 5. RX-900 AUTO A M AUTO V L R M A Averaging Systems A M AUTO
  • 6. 3D Control Systems Mill to Grade based on Position
  • 7. Proper Maintenance
  • 8. Proper Maintenance
  • 9. Proper Holder Wear
  • 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. 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. 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. Look at the Holders Caliper set at EXACTLY 2”
  • 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. Novatec Diamond, Kenamental • Both fit into a Kenametal quick change holder Both are the same height
  • 16. Tooth Pattern
  • 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. Clean up your mess Our shovel is on the water truck. The automatics will take that out…
  • 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. Line Spacing and Texture
  • 21. 5/8” (16mm) Triple Wrap Lacing Pattern
  • 22. 5/8” 5/8” ≈⅛” 5/8” (16mm) Triple Wrap Lacing Pattern
  • 23. 5/8” (16 mm) Triple Wrap at 30 fpm
  • 24. 2/10” (5mm) Triple Wrap Lacing Pattern
  • 25. 0.2” ≈1/16” 2/10” (5mm) Triple Wrap Lacing Pattern
  • 26. 2/10” (5mm) Triple Wrap Lacing Pattern
  • 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. 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. 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. 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. Forward Speed
  • 32. Advance Rate = 30 fpm Drum Diameter = 46” Drum Speed = 100 rpm Advance Rate = 30 fpm Machine Advance 3.6” 0.071”
  • 33. 30 fpm
  • 34. Advance Rate = 60 fpm Machine Advance 7.2” 0.28” Advance Rate = 60 fpm Drum Diameter = 46” Drum Speed = 100 rpm
  • 35. 60 fpm
  • 36. Advance Rate = 120 fpm Machine Advance 14.4” 1.16” Advance Rate = 120 fpm Drum Diameter = 46” Drum Speed = 100 rpm
  • 37. 120 fpm
  • 38. 30 fpm vs. 120 fpm 2.3 miles in a day vs. 9.1 miles in a day
  • 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. 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. 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. Drum Lacings Scroll Start Comparisons Triple Wrap Double Hit Quad Wrap
  • 43. Double Hit Drums Above Double hit Quad wrap drum Standard triple wrap drum Below
  • 44. Pattern Comparison 7/8” DHQW at 100 FPM5/8” Triple Wrap at 100 FPM
  • 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. 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. Thank you & Slow Down

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