The Best Drill Bits for Metal, Tested - best carbide insert for mild steel

 2024-06-22 00:42:25

Thoughtful considerations will set you on a shortened path to the most optimized solution once cutter meets metal.

Strength and rigidity are critical for the tiny end mills employed on the Kern, but the broader shop also sees plenty of work that requires tools with length-to-diameter ratios that increase the risk of breakage and vibration, Mr. Sweeting says. Reduced necks also improve access to part features because they’re less likely to interfere with the cutting action, regardless of part size or tolerances.

Formnext Chicago is an industrial additive manufacturing expo taking place April 8-10, 2025 at McCormick Place in Chicago, Illinois. Formnext Chicago is the second in a series of Formnext events in the U.S. being produced by Mesago Messe Frankfurt, AMT – The Association For Manufacturing Technology, and Gardner Business Media (our publisher).

Mitsui Seiki USA Inc. appoints Joseph Farkas as its director of sales West and Terry Ritterbush as its director of sales East.

Ever wonder what sets Top Shops apart from the competition? Dive into their award-winning practices and explore behind-the-scenes strategies for operational excellence.

Heidenhain and Acu-Rite Solutions are offering several hands-on experiences at their booth this year, as well as internal components that reduce energy use.

Legacy Precision Molds takes us on a tour of their moldbuilding facility. They've recently implemented two automated 5-axis cells for metal and graphite machining that run lights out during nights and weekends.

AccuRounds has created synergy between culture and technology, driving a commitment to customer satisfaction and continuous improvement.

Chiron Group combines the best of both worlds at IMTS 2024, featuring live demonstrations of their Micro5 and Mill 2000 machines, alongside a cutting-edge virtual showroom. This innovative approach allows visitors to explore Chiron’s full product lineup without the logistical challenges of transporting large equipment.

FANUC’s IMTS 2024 booth includes real-time demonstrations that show the abilities of its equipment, including robots, controllers and machine tools.

Women in Manufacturing is excited to announce that the 2024 SUMMIT will be a hybrid event — both an in-person and virtual experience. Both program offerings will enable you to grow through education and connections that are insightful, meaningful and actionable. Join Women in Manufacturing Oct. 6-9, 2024, in Boston or digitally for an event filled with plant tours at leading manufacturing facilities, professional development sessions, roundtable discussions on important topics, and inspiring keynotes. All while engaging and interacting with peers through social and networking events! __PRESENT __PRESENT

These components are inserts for expanded-beam fiber-optic cable connectors that use lenses to focus and transmit light from one optical fiber to another. The bores holding the optical fibers must be held to within +1.5/-0 microns of nominal diameter and an N4-level (0.2-micron) surface finish. Although most of the part (as well as other components for the same job) is machined on a Swiss-type lathe, operations requiring that level of precision are left to the shop’s Kern Evo machining center.

User-friendly inspection software for CNC machining centers is shown monitoring measurements between and after machining while performing SPC based on recorded measurement values.

Are AMRs the next big trend in job shop automation? System 3R’s IMTS booth will emphasize both its specialty EDM tooling and its automation products, including an autonomous moving robot.

Purchased shortly after the Evo, the shop’s Zeiss O-inspect CMM offers both touch-probe and optical measurement capability. The latter is particularly useful for features too small or sensitive to reach with a probe. Even in an application like that, however, the probe might be required to indicate the workpiece if the part is not perfectly square to the camera.

Heidenhain and Acu-Rite Solutions are offering several hands-on experiences at their booth this year, as well as internal components that reduce energy use.

Yet, the greater the comfort level with trying new things on the Evo, the greater the comfort level in doing so out in the broader shop as well, regardless of whether customer specifications require it. “We’re pushing the envelope a lot more,” Mr. Reypa says. For instance, he says the shop is more likely to use specialty tools in cases when it previously would have defaulted to straight-flute carbide end mills. One recent case involved roughing aluminum at 10,000 rpm and 200 inches per minute with a ¾-inch end mill designed specifically for that material. “Five or six years ago, we’d have probably used a high speed steel regrind and gone slow and steady with it,” he says.

When revising part designs, investigate the 3D CAD, the 2D drawing and the part’s functional requirements to determine which details should be tightened up.

However, Mr. Sweeting emphasizes that even the most carefully engineered, well-maintained machine and a highly controlled environment haven’t been enough. Without learning to optimize the process for specific jobs, Integral Machining never would have been prepared to meet tolerances that match or even exceed the Evo’s advertised capabilities of ±2 microns on the part.

Tool-holder-spindle-machine combinations each have a unique dynamic response in the same way that each person has a unique fingerprint, which can be revealed using modal testing.

The L.S. Starrett Co. has been manufacturing precision measurement tools in Athol, Massachusetts, since 1880. Attention to U.S. manufacturing often focuses on reshoring manufacturing from other countries, but Starrett never left. The facility in Athol employs hundreds and produces thousands of tools that remain vital for measurement in machining and other fields.

As lessons learned in extreme-precision operations continue to percolate through the shop, Mr. Reypa, Mr. Sweeting and crew are eyeing their next step. In fact, Mr. Reypa says they might have already purchased a Kern Micro, the builder’s successor to the Evo, if it weren’t for a less-than-favorable exchange rate between the Eurozone and Canada. Whatever the future holds, Integral Machining is eager to expand its capability and capacity for jobs requiring tolerances measured in single-digit microns. If past experience is any indication, more of that work will pay off not only in direct revenues, but in a more capable shop as a whole.

New tool paths. Using the same tool for multiple features wouldn’t work very well without efforts to maximize tool life, and Mr. Sweeting credits 3D Systems’ Cimatron CAM software for much of the gain. Initially purchased to replace a system that didn’t offer sufficient resolution or 3D capability for operations on the Evo, this CAM package facilitates the use of smoother tool paths that provide better control over cutting forces. One example is trochoidal milling, a slot-milling strategy employed for parts like the microfluidic test plate in the second picture. Feeding the tool in a looping, curlicue pattern enables precise control of radial depth of cut, a particular concern when the goal is to mill the entire slot with the same cutter. With surface finish of 0.2 micron, changing tools would have been risky on that job. It also likely would have been less efficient, he adds.

Zoller’s open house in Ann Arbor, Michigan, provided attendees with a glimpse of the connectivity and efficiency the company’s products offer to users.

Sunnen Products Co. is celebrating its 100th anniversary, highlighting the history of its line of honing and precision solutions.

Ceratizit USA announces it has appointed Carlos Garza as its business development leader for the oil and gas industry sector.

Integral Machining LTD has long touted its expertise in high-precision machining, but that term has taken on new meaning during the past few years. Serving customers in such industries as microfluidics and photonics has pushed this 6,000-square-foot, Toronto-area shop to institute machining processes that achieve tolerances measured in single-digit microns.

Working closely with customers and making careful investments has enabled this Wisconsin machine shop to tackle difficult jobs with tight deadlines as a core part of its business.

Looking to automate your shop floor? The Automated Shop Conference (TASC) will connect shops with experts who can advise them through this transition.

Since moving into work requiring extreme precision, Integral Machining has been using more specialized tools on other jobs as well. Designed specifically for aluminum, this Alumigator 0.5-inch-diameter end mill from G.W. Schultz Tool features variable flute geometry designed to create small chips and a polished rake to ensure chips don’t stick to the cutter.

Technology and process changes spurred by adding extreme-precision parts to the shop’s mix of go beyond machining operations. For instance, the previous CMM simply wasn’t sufficient for micron-tolerance work, Mr. Reypa says. Today, the shop uses an O-Inspect multi-sensor system (optical and touch probe) from Carl Zeiss Industrial Metrology. As was the case with the Evo, measuring difficult work on this machine spurred across-the-board improvements in quality control.

Job shops are implementing automation and digitalization into workflows to eliminate set up time and increase repeatability in production.

The oscilloscope has also proven invaluable for determining “sweet spot” cutting parameters that provide the smoothest machining for various cutting tools. The basic idea is to ensure the cutting edges hit the workpieces in time with the natural frequency at which the machining center is prone to vibrate with that particular tool. In one recent instance, a manufacturer’s recommendations specified 48,000 rpm for effective cutting of microfluidic channels in Grade 5 titanium with a 0.006-inch-diameter, four-flute end mill—a speed that’s very close to the Evo’s 50,000-rpm limit. However, testing different parameters with the oscilloscope revealed that the tool would perform far better at 39,000 rpm—that is, the spindle speed at which the Z-axis line stayed flattest throughout the cut.

The choice between buying a new machine or refurbishing the current one will become clear after a thorough assessment of the machine.

Automation is no longer a luxury in manufacturing today – it’s a necessity. The Automated Shop Conference (TASC) will connect job shops with experts who offer advice and considerations for this process.

This presentation focuses on the vital role that linear and angular encoders play in ensuring precision in machine tools. Attendees will learn about the common challenges compromising accuracy, such as thermal expansion, mechanical misalignments and vibration. Whether you're an OEM, integrator, or machine operator, this webinar will offer valuable insights into optimizing CNC performance. Agenda: Challenges to CNC machine accuracy Understanding encoder technology How encoders address accuracy challenges

Horn USA’s new booth concept is designed to enable attendees to (literally) get a better feel for its various tooling offerings.

Modern Machine Shop is the leading publication and media brand in North America devoted to CNC machining. MMS combines unprecedented editorial access to manufacturing facilities with decades of experience to provide long-form content that is both insightful and impactful. About Us

Installing this machine was in many ways more like setting up a piece of metrology equipment than a piece of machining equipment, says production manager Andrew Sweeting, the machine’s chief operator. Although the shop has long segregated its coordinate measuring machine (CMM) from the broader operation, accommodating the new machining center required closing off an even larger space surrounding the quality control area. The environment in this 1,100-square-foot section of the shop is tightly controlled. Temperature is held to a constant 20°C (there’s no turning down the thermostat at night here), and five hygrometers monitor humidity. To prevent yaw, pitch and other errors from creeping into the structure with continued use, Mr. Sweeting conducts a machine calibration routine every month. Kern representatives also visit approximately every 18 months to conduct an even more thorough calibration using a Heidenhain KGM grid encoder.

Variable tool geometry. Success in micromachining has also led the shop to prioritize cutting tools with variable helix angles, rake angles and flute spacing. Applications on the Evo leave no room for chatter, and symmetrical end mills are particularly vulnerable, Mr. Sweeting says. Identical cutting edges create vibrations at identical frequencies, vibrations that build on one another as each successive edge strikes the workpiece. Variable-geometry tools suffer no such buildup. The number of flutes on a tool is also important. The greater the number of flutes, the less likely it is that one flute will exit the material before the next one enters it, thus creating a “hammering” action, Mr. Sweeting explains. Additionally, spreading cutting forces and chip generation among more flutes generally results in smaller chips and smoother surface finishes.

FABTECH 2024 will be held October 15-17, 2024, in Orlando, Florida, at the Orange County Convention Center. FABTECH provides a convenient ‘one-stop shop’ venue where you can meet with world-class suppliers, discover innovative solutions, and find the tools to improve productivity and increase profits. There is no better opportunity to network, share knowledge and explore the latest technology, all here in one place. Future U.S. Show Dates and Locations 2025 – September 8-11 at McCormick Place in Chicago, IL 2026 – October 21-23 at Las Vegas Convention Center in Las Vegas, NV 2027 – September 13-16 at McCormick Place in Chicago, IL

Tool-holder-spindle-machine combinations each have a unique dynamic response in the same way that each person has a unique fingerprint, which can be revealed using modal testing.

Each tool setting technique has merit, and it depends on where you are as a shop and the type of work you do, as cost and efficiency all come into play.

Structured light scanning is used to create a digital twin of a manufactured part, but we must understand the measurement reproducibility to best use the data.

From quadruped robot dogs, to an in-booth putting green where you can test out a new golf putter, to a 3D-printed car and more, attendees enjoyed cutting-edge technology and innovations all week long. Take a look to see what (or who!) you might have missed this week!

Join Mahr for an informative webinar to discover the latest advancements in precision measurement, designed to elevate your quality assurance processes and unlock peak productivity. It'll explore cutting-edge technologies — such as modern height gages and contour measuring systems — along with their applications, benefits and technical capabilities. Discover the power of height gages: Learn how intuitive and sophisticated height gages can revolutionize your measurement processes, enabling quick and accurate results in inspection and production areas. Explore the practical functions and ease of use that make height gages an ideal solution for manufacturers seeking high-performance and reliable measuring technology. Examine sample applications and industries where height gages excel, such as qualifying first parts, inspecting incoming parts and measuring series of parts in industries like aerospace, automotive and medical. Unlock efficient contour measurement: An introduction to the latest contour measuring technologies that enable fast, simple and comprehensive contour measurement in the production environment. Discover how these innovative solutions ensure reliable measurements, saving time and increasing efficiency while measuring a wide range of workpieces. Learn how to streamline your contour measuring process with speed and simplicity, achieving fast and precise measurements with incredible versatility. Register now and discover how to unlock peak productivity with new innovations in precision measurement. Agenda: Insights into the latest precision measurement technologies and their applications Understanding of how to improve quality assurance processes and increase productivity Knowledge of how to select the right measurement solutions for your specific needs Tips on how to optimize your measurement processes for maximum efficiency

Lee Wimmer invited us to tour his second-generation family-owned machine shop in Perkasie, PA. This video explores the production processes behind precision-machined parts for both Wimmer Custom Cycle and LS Wimmer Machine Co., and shows how ingenuity and determination are still at the heart of American manufacturing. Today, both companies are now managed by Wimmer’s three sons.

Andrew Sweeting, Integral Machining’s production manager and the chief operator of the Kern Evo, demonstrates the Heidenhain CNC’s oscilloscope. This function helps hone in on sources of error through real-time displays of how far each axis deviates from its programmed position.

There are usually better solutions to chatter than just reducing the feed rate. Through vibration analysis, the chatter problem can be solved, enabling much higher metal removal rates, better quality and longer tool life.

ANCA CNC Machines is celebrating its 50th anniversary as a global producer of CNC tool and cutter grinders.

Microfluidics industry R&D applications have called for milling channels with extremely smooth finishes into plastic or, as seen here, titanium plates. Trochoidal tool paths facilitated fine control of radial depth of cut, thereby ensuring consistent cutting forces and the ability to finish both sides of this 0.006-inch-diameter channel and achieve an N4 (0.2 micron) surface finish in a single pass. For work this demanding, the shop has also been known to temporarily turn off thermal compensation in the Z axis to prevent a compensating movement from marring the surface.

When Puneet and Neelam Neotia moved from India to the United States several years ago, they brought with them a family background in manufacturing and CNC machining. Now the couple is working to get their startup machine shop off the ground, sourcing new customers and getting the word out about their shop in Clarksville, Indiana. The couple — proud to publicize their "Made in the USA" parts — is leveraging family connections and manufacturing capabilities back in India, but not in the way that some people assume.

In the latest episode of our View From My Shop series, MMS Editor-in-Chief Brent Donaldson visited the JN Shapiro Watches headquarters and production facility where Founder Joshua Shapiro—a history teacher turned watchmaker—realized his dream of "making a watch from scratch and everything in it."

When it comes to utilizing the spindle’s power, there is a lot of headroom at the upper limits, provided it’s in short bursts. Be mindful of your time at these loads so you don’t stall out.

A closer look at the fiber-optic connector inserts. The optical fibers are contained within ceramic sleeves, or ferrules, that fit snugly within 2.5-mm-diameter bores, which feature 3-mm counterbores on the connecting ends to accommodate the lenses.

Weldon Solutions is demonstrating three grinders at IMTS 2024. Though they differ in size and use case, all feature the company’s hallmark customizations.

Get sensible, real-world automation solutions during this half-day workshop co-located with IMTS 2024.

Manufacturers continue to feel the pressure to reduce costs, increase efficiencies and meet their sustainability strategies. As the industry evolves to keep pace with these priorities, there are opportunities within metalworking processes to use less resources with advanced lubricants and technical expertise. Agenda: An overview of metalworking lubrication Evolutions in metalworking lubrication Experience on the shop floor Key takeaways

JD Machine, 2024’s Top Shops Honoree in Human Resources, embodies its “Education for Life” core value with a robust apprenticeship program and significant continuous improvement efforts.

Consistent machine motion. Ensuring proper positioning for patterns of features, whether relative to one another or any particular datum, can be particularly difficult for work that requires the Evo. For example, the positions of the bores on the fiber-optic connector inserts must be held within ±1.5 microns. In scenarios like this, programs for the Kern always direct the machine to return to a center position after drilling each hole, rather than moving from one hole to another in sequence. This strategy ensures that X- and Y-axis movement to and from each hole—and by extension, acceleration, deceleration, breaking distance, backlash and so forth—is as consistent as possible. Although not usually necessary for work that doesn’t require the precision of the Evo, this strategy always provides peace of mind when feature position is critical, Mr. Sweeting says, particularly when multiple tool changes or other factors add potential for variation.

Standards for surface finishes and profiles are not static; they change as technology changes or new processes come along that need to be considered.

The latest episode “Made in the USA” podcast explores a company that uses collaborative robots, one of the key tools helping US machine shops and other manufacturers compete with lower cost countries by automating production.

Rob Guiao, Chris Hall and Bassanio Peters will demonstrate relatable situations to equip you with data to improve predictability, future-proof operations and maximize ROI. Agenda: Explore the importance of data in decision-making, especially for facility upgrades or new projects Learn how comprehensive solutions for manufacturing and construction projects can improve predictability and ROI See real demonstrations of machine integrations, facility layouts and automations to ensure proper throughput and integration

New tech center is serving as a cutting-edge showroom and a technological hub for advanced machining applications.

Part of Major Tool’s 52,000 square-foot building expansion includes the installation of this new Waldrich Coburg Taurus 30 vertical machining center.

Effective team collaboration is a critical component of success in today’s manufacturing world. With cloud-based technologies that make it easy for team members to brainstorm and problem solve remotely from various locations, design-to-manufacturing processes can become faster and more efficient. This webinar will demonstrate how fully integrated CAM software can be utilized with 3DExperience SolidWorks in a seamless work environment to accelerate product development. Agenda: See how HCL CAMWorks can be used as an add-in for all SolidWorks applications working with the cloud-based 3DExperience platform Learn how fully integrated CAD/CAM saves significant amounts of time during the design to manufacturing process Gain a new understanding of how software can connect users worldwide to accelerate product development Watch a demonstration of team collaboration using platform tools in the CAD/CAM software environment

Thoughtful considerations will set you on a shortened path to the most optimized solution once cutter meets metal.

Complementing error controls inherent to machine and environment begins with steps that are relatively simple. However, that doesn’t make them any less essential. One example is allowing the machine to warm up before cutting begins. The length of the warmup depends on the application, Mr. Sweeting says, ranging from an hour or so for workpieces that respond well to heat to all night for more demanding materials. He adds that he often warms up the smallest tools for 10 minutes or so by letting them run at operational speed until the carbide expands. To manage vibration, he sometimes posts a sign to warn operators of the VMC on the other side of the door to avoid heavy roughing while the Kern runs. “We can’t tolerate any variation,” he says.

SSP’s commitment to adopting the latest machining technology benefits not only the business, but its employees as well.

While there are many changes to adopt when moving to five-axis, they all compliment the overall goal of better parts through less operations.

The Walter Turn toolholder features rake-face cooling to help break and control chips, and double flank-face cooling directly at the cutting edge to extend tool life.

Cam-actuated Swiss lathes are still the fastest way to process many parts. By adding modern bar feeders, this shop has dramatically improved their utilization with the ability to work unattended, even in a lights-out environment.

AccuRounds has created synergy between culture and technology, driving a commitment to customer satisfaction and continuous improvement.

Part of Major Tool’s 52,000 square-foot building expansion includes the installation of this new Waldrich Coburg Taurus 30 vertical machining center.

New U.S.-based event announced in 2021 finally debuts next year: focuses on complete additive manufacturing value chain. More at formnextchicago.com.

Walter USA has acquired PDQ Workholding, intending to strengthen its offering of workholding products and develop future cutting tool sales.

FANUC’s IMTS 2024 booth includes real-time demonstrations that show the abilities of its equipment, including robots, controllers and machine tools.

That machining center has proven capable indeed since its installation in 2010, he says. The Evo’s precision begins with a C-frame construction that keeps the spindle fixed in Z and relies on table motion for all other axis travels. It also features a polymer concrete base that, according to Kern, is stiffer and more resistant to vibration than the cast iron or weldment frames typical of many machine tool designs. Glass scales and roller-seated, prestressed, prismatic linear guides contribute to machine resolution of 0.1 micron. Meanwhile, circulating water keeps all components, including the axes, spindle, electrical cabinet and coolant tank, at a constant temperature of 20°C. The electrical cabinet is separated from the rest of the machine, as is the chiller that cools the water, to prevent the heat generated by these components from affecting precision.

Ever wonder what sets Top Shops apart from the competition? Dive into their award-winning practices and explore behind-the-scenes strategies for operational excellence.

Though most frequently used for diameter measurements, an air plug and platen can be readily configured to measure perpendicularity.

Slimmer tool necks. Virtually every end mill employed in micromachining has a reduced neck; that is, the neck of the tool is a solid cylinder that’s smaller in diameter than both the business end and the shank. This construction offers greater rigidity and strength than tools with flutes extending the entire length of the neck, because the cross section of the flutes is relatively thinner and weaker.

For example, the 2.5-mm-diameter cubic zirconia ring gage in the last picture was purchased for one of the shop’s first applications requiring single-digit-micron tolerances on small bores. Calibrating the machine with a larger artifact wasn’t enough to ensure consistent measurements. The lesson inherent to that application—that the artifact used for calibration should match the geometry and size of the feature to be measured as closely as possible—has since been applied on a number of jobs in the broader shop. “If we need to check a bore to a couple of tenths with a snap gage, we might get a special ring gage made that’s accurate to within five decimal places. Then we know we’re beyond accurate,” Mr. Reypa says.

Each tool setting technique has merit, and it depends on where you are as a shop and the type of work you do, as cost and efficiency all come into play.

Across a range of technical presentations aimed at small and mid-sized job shops, the first-ever Automated Shop Conference (TASC) offered insights into several automated technologies, implementation strategies, shopfloor training tips, and even the untapped power of automated coolant delivery.

Such experimentation has led the shop to prize certain tool characteristics that it never would have considered if it hadn’t purchased the Evo. The following outlines a few examples of those characteristics, as well as other changes driven by a more open-minded, forward-thinking attitude and greater willingness among staffers to push themselves and their equipment to new limits.

The Automated Shop Conference (TASC) will give shops of all sizes and production volumes key insights and practical guidance on how to implement automation.

Take a look inside James Engineering, a high-end CNC Deburring OEM that became a job shop when they decided to produce their own parts in-house.

Old-world craftsmanship combines with precision machining on a vertical machining center and Swiss-type lathe to produce some of the only U.S.-made mechanical wristwatch movements.

One benefit of this feature is reduced troubleshooting time. For instance, if Y-axis motion is on target but X-axis motion is not, Mr. Sweeting might conclude that a programming error resulted in too much material being left on one side of the part. “With a 1-inch end mill, leaving an extra 0.001 inch might not make a difference, but that’s 25 percent of the diameter of a 0.004-inch end mill,” Mr. Sweeting points out.

Same tool, multiple features. One of the most difficult challenges associated with the fiber-optic connector inserts was ensuring the lenses seated in the counter-bored holes were lined up well enough. More specifically, the problem was ensuring concentricity between the 2.5-mm-diameter bores and the 3-mm-diameter counterbores. With a helical tool path, the counterbores and bores could be machined with the same end mill. This strategy kept the lenses straight enough to keep light loss within specification (no more than 1.5 dB).

In this webinar, industry-leading experts will demonstrate how additive manufacturing can revolutionize your operations and answer the question: Can you afford not to? From rapid prototyping to robust fixturing and specialized custom tooling, it’ll showcase the diverse applications that can drive your business forward in a time where cost and time saving can be crucial. Discover how to reduce costs, accelerate production cycles and achieve unparalleled design freedom through the strategic integration of 3D printing technology. Phillip’s panel of seasoned professionals will share real-world examples and practical insights to help you understand the potential of additive manufacturing. Learn how to overcome production challenges, improve product quality and gain a competitive advantage. It will explore the cost-benefit analysis of 3D printing — including material and labor savings — as well as the potential for increased revenue. Join this webinar to discover why additive manufacturing is no longer a luxury, but a necessity for success. Agenda: Prototyping example: quick-change prototype Custom tooling real-world example: press brake, tube bending die CMM fixturing and workholding example: CMM fixture and soft jaw

The first optic connector insert bores emerged from the machine slightly bell-shaped, a defect resulting from the cutter deflecting off chips that didn’t evacuate. This fixture features a coolant-line connection and internal channels that enable blasting fluid (and chips, which are more like powder in this case) upward through the bores. The clamps are Uniforce-brand models from Mitee-Bite. Initially purchased for consistent clamping forces that are essential to operations on the Evo, these devices have since been widely adopted throughout the shop.

Weldon Solutions is demonstrating three grinders at IMTS 2024. Though they differ in size and use case, all feature the company’s hallmark customizations.

What’s more, the benefits of attaining micron-level machining capability extend beyond the opportunity to compete in a less crowded arena. Pushing the Evo has required the staff to push their own thinking, too, Mr. Reypa says, and lessons learned often translate to less demanding work in the broader shop. As a result, Integral Machining has become a more efficient and effective machining operation overall, and thus, a better partner for all customers, whatever their requirements, Mr. Reypa says.

New tech center is serving as a cutting-edge showroom and a technological hub for advanced machining applications.

Did you know that the show was postponed for WWII? Or that McCormick Place was expanded in the ’70s just to accommodate IMTS? A fascinating look at the show’s history from 1927 to today.

Understanding all the things that contribute to a machine’s full potential accuracy will inform what to prioritize when fine-tuning the machine.

Clean, burr-free cutting is fundamental to competitiveness for a shop that specializes in micro-machining complex geometry from some of the softest materials in the industry.

Integral Machining was particularly attracted to micron-tolerance work because much of the right kind of capacity was already in place before installing the Evo, Mr. Reypa says. Founded in 1989 in Oakville, Ontario, the shop has long occupied a niche in small, high-precision parts, particularly for the aerospace and medical industries. Go-to machining resources include four three-axis VMCs with aftermarket rotary fourth-axis attachments, as well as three Swiss-type lathes. Although none of these machines offer the precision of the Evo, that level of precision isn’t required for every feature of every part. In fact, only about 30 percent of jobs require micron-tolerance operations, and those operations are usually limited to a few critical features. As a result, the 11-employee shop has been able to move into new segments of work while filling capacity on more than just its most capable machining center.

Advanced CNC functionality and sweet-spot harmonics aside, running extremely tiny tools at extremely aggressive spindle speeds took some getting used to. “I’d never in my life spun a 6-thou end mill that costs $50 apiece at anything close to 50,000 rpm, and it was a bit nerve-wracking at first,” Mr. Sweeting admits.

Because of the high material removal rate creep-feed grinding can deliver in challenging materials, grinding might not be just the last step in the process—it might be the process.

Attend TASC, The Automated Shop Conference, in Novi, Mich on Oct. 11, 2023 for a comprehensive look into how to use automation to transform your machine shop.

This 2.5-mm-diameter cubic zirconia ring gage was purchased for a job that required bores with particularly tight tolerances. Calibrating the CMM with artifacts that closely match the size and geometry of measured features is one of many lessons from such work that have translated to the broader shop.

So far, Made in the USA has looked into system-wide effects of broken supply chains, automation, skilled workforce issues and our perception of manufacturing jobs — examining each topic through a prism of individual experiences. For this final episode for Season 1, let’s look at one more system-wide question and bring it back to personal perspectives: Is there today a new dawn, a new moment for American manufacturing?

When it comes to utilizing the spindle’s power, there is a lot of headroom at the upper limits, provided it’s in short bursts. Be mindful of your time at these loads so you don’t stall out.

Incremental mode can be more advantageous when programming sculptured surfaces or for certain hole-machining canned cycle applications.

Although instances of using trochoidal milling in the broader shop are rare, the same principles have been applied to improve tool life and productivity there as well. For example, Mr. Sweeting credits Volumill, a toolpath engine within the software, for generating tool paths that keep the load on the cutting tool and spindle within programmed limits by avoiding sharp changes in direction or tool engagement.

Refined machines at EROWA are handling heavier loads, while its precision workholding enhances stability and rigidity.

Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.

Q-Mark has built its metrology business by providing what customers need, when they want it. This goes for its IMTS booth, too, with free drinks alongside custom technology.

The MB45 series is designed to deliver the low cutting force benefits of positive inserts and the fracture resistance of negative inserts.

Runout, temperature, wear and other factors affecting the cut can vary with different tools, however carefully mounted in the toolholders and however exacting the tool-changing mechanism, Mr. Sweeting explains about the success of this strategy. Although particularly impactful for operations on the Evo, the same principle applies at any scale.

Are AMRs the next big trend in job shop automation? System 3R’s IMTS booth will emphasize both its specialty EDM tooling and its automation products, including an autonomous moving robot.

Take a look inside James Engineering, a high-end CNC Deburring OEM that became a job shop when they decided to produce their own parts in-house.

Thoughtful considerations will set you on a shortened path to the most optimized solution once cutter meets metal.

Fryer Machine Systems Inc. presents its TC Series of CNC machining centers for high-performance cutting, accuracy, reliability and ease of use.

The shop’s entry into these markets was the result of a deliberate push to differentiate itself in the immediate wake of the economic downturn, says Peter Reypa, president and founder. Enter Kern Precision Inc.’s five-axis Evo, a machining center with positional accuracies of ±0.5 micron that was installed in 2010. That’s sufficient to achieve ±2 microns on the workpiece. Still, even this machine must be pushed to its limits to satisfy the stringent requirements that characterize work from the shop’s newer customers. Efforts to that end have consisted largely of eliminating even the most seemingly insignificant sources of error through environmental controls, careful calibration routines, advanced CNC functionality, and new cutting tools, software and machining strategies.

Working closely with customers and making careful investments has enabled this Wisconsin machine shop to tackle difficult jobs with tight deadlines as a core part of its business.

Though most frequently used for diameter measurements, an air plug and platen can be readily configured to measure perpendicularity.

Absent tools with multiple, variably spaced and angled flutes, the shop probably couldn’t machine parts like those in the first and fourth pictures, Mr. Sweeting says. These inserts for expanded-beam fiber-optic cable connectors use the green lenses to focus and transmit light from one optical fiber to another. Finish-machining the bores that hold the lenses and optical fibers to an N4-level (0.2-micron) surface finish involved using a 2-mm-diameter, 10-mm-long, three-flute end mill to shave off only 100 microns of material in a helical motion. Work in the broader shop isn’t nearly as demanding, but the shop often leverages such cutters to boost the performance of any suitable operation.

In this episode of Made in the USA, several executives and senior staff at Hardinge give their first-person account of how they formulated the plan to shift the manufacturing of its milling and turning product lines from its Taiwan plant to its plant in Elmira, New York, the major challenges they encountered and the rewards that made it worth the effort.

Learn more about the variety of technology and machinery Hwacheon Machinery America, Inc. is featuring at its IMTS 2024 booth.

FANUC’s IMTS 2024 booth includes real-time demonstrations that show the abilities of its equipment, including robots, controllers and machine tools.

Misapplication of these important CNC features will result in wasted time, wasted or duplicated effort and/or wasted material.

FANUC’s IMTS 2024 booth includes real-time demonstrations that show the abilities of its equipment, including robots, controllers and machine tools.

Different tools and machining strategies have driven this shop to seek new efficiencies beyond its most demanding work and most capable machining center.

Entrepreneur Scott Colosimo found early success in China producing parts for his Cleveland-based motorcycle company in the mid-2000s. This is the story of how IP theft issues overwhelmed the business, prompting Colosimo and his team to start over from scratch — and move production back to the United States.

One strategy for zeroing in on inconsistencies, including those that don’t start with the machine itself, is to measure axis deviation with the oscilloscope function of the machine’s Heidenhain iTNC530 CNC. Typically used by machine tool builders and distributors for axis tuning, the oscilloscope measures electrical signals to determine the difference between the axes’ programmed positions and actual positions. Results display as two-dimensional waveforms for each axis (Mr. Sweeting likens the display to a heart monitor).

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