Why so cross? - tungsten carbide insert definition

 2024-06-18 23:19:09

This probably isn’t groundbreaking or anything, but for small screws I’ve had good luck pre-heating them with a soldering iron, then run it in and out of the part to form the thread. The thread forms a little nicer than just forcing the plastic around and potentially separating along the layer lines.

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

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.

The use of solid ceramic end mills is on the rise, says Thilo Mueller, manager of solid end milling tools with Kennametal. And in a way, that news is less dramatic than it might sound, because solid ceramic end mills are arguably easier to use than carbide ones. Shops applying them need not make special process changes. Contrary to what is often assumed about ceramic tooling, these end mills do not require runout any better than what is used for comparable carbide tools. And because the tools perform effectively when machining dry, considerations related to coolant become irrelevant.

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Love pretty much everything Matthias does, but AFAIK we haven’t covered them on Hackaday. That was probably an oversight.

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

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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.

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

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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

And by far the majority of the time the intended use case is for the force to be pulling the insert out in the normal direction (eg. you’ve printed an enclosure with a lid) as these test results are intended for the average maker.

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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.

[Stefan] also looked at torque resistance, and found no substantial difference between the three insert types. Indeed, none of the inserts proved to be the weak point, as the failure mode of all the torque tests was the M3 bolt itself. This didn’t hold with the bolt threaded directly into the plastic, of course; any insert is better than none for torque resistance.

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.

Not that surprising given the design, but that’s at the first time you tread the M3 screw in. What happens after you do it 10 times? Maybe the insert is better at that point than not having it?

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.

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.

Same here. A captured nut or embedded in the opposite side of insertion. Bolt might fail first at that point

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

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

cnSEE from All World Machinery Supply combines easy installation and monitoring across multiple machines.

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.

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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.

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

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Here is video of what that productivity looks like. The material here is Inconel 725. The “sparks” seen in part of this footage are a result of the tool using heat as part of its cutting action. What look like sparks are actually the material being converted to powder:

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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.

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

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.

If this sounds familiar, it’s with good reason: we covered [Stefan]’s last stab at assessing threaded inserts back in March. Then, he was primarily interested in determining if threaded inserts are better than threads cut or printed directly into parts. The current work is concerned with the relative value of different designs of threaded inserts. He looked at three different styles of press-in inserts, ranging in price from pennies apiece to a princely 25 cents. The complexity of the outside knurling seems not to be correlated with the price; the inserts with opposed helical knurls seem like they’d be harder to manufacture than the ones with simple barbs on the outside of the barrel, but cost less. And in fact, the mid-price insert outperformed the expensive one in pull-out tests. Surprisingly, the cheapest inserts were actually far worse at pull-out resistance than printing undersized holes and threading an M3 screw directly into the plastic.

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

There are so many things wrong with this video. 1.Inserts are to be molded in when the plastic is injection molded. 2.Inserts are installed ultrasonically, not with a soldering iron 3. inserts are to to be pulled from the opposite side of the material. If your snapping the heads off of the fasteners you are over torquing the product. ( torque for that size screw is in the neighborhood of 5 inch pounds )

I’d like to see tests with embedded sliding and/or pronged t-nuts. I suspect that they would work much better to resist both pulling and torque.

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).

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

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

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.

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.

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

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

I can’t watch the video right now bit this bit throws up a question in my mind: “Surprisingly, the cheapest inserts were actually far worse at pull-out resistance than printing undersized holes and threading an M3 screw directly into the plastic.”

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.

Stefan does remark that on his video, saying that if you are going to bolt-and-forget an undersized hole on the print is good enough, and that if you are going to constantly insert and remove the screws even the cheap insert is a better option.

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

As a result, ceramic tools are roughing tools. Ultimately, carbide cutting edges still must perform the final finishing cuts. They do so after the ceramic end mill has delivered high productivity by quickly removing away most of the material.

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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.

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.

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!

While we’re talking head to head tests, no love for Matthias Wandel’s Gorilla glue vs. wood glue shootout (https://www.youtube.com/watch?v=MUWu-N85oXM) and pocket hole vs. mortise and tenon joint comparison (https://www.youtube.com/watch?v=apsH8eBfjVA)?

Even chinesium is better than plastics in handling repeated tightening. Self taping screws are used when that’s not an issue.

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.

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

Many are aware of ceramic cutting tools only as inserts, Mr. Mueller says. The solid-body ceramic end mill is a complement to this type of tool—useful for the same applications, but at diameters too small for an inserted cutter.

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."

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

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

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

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.

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

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

But the right application remains key, he says. Relative to carbide, solid ceramic tools are still expensive. Not only is the purchase price higher, but ceramic also offers little to no opportunity for extending useful life through regrinds. The tools therefore require applications in which a dramatic productivity gain over carbide easily justifies the cost difference. Even iron and titanium alloys don’t necessary allow for this, but in nickel-based metals, ceramic tools routinely do deliver this dramatic improvement.

Horses for courses. Maker videos are intended to help the maker community make *their* stuff better.

The new SolidMeister barrel end mills are efficient tools for complex 3D-surfacing operations used in mold making, orthopedic implants and the machining of other freeform surfaces.

I’d actually like to see what happens when yo try to pull the threaded insert out the other way – in the opposite direction from how they’re inserted. I’d imagine the plastic would break before the insert pulls out, depending on how much plastic is backing it up and the diameter of the clearance hole needed to pass the fastener. Not suitable for every application, of course, but I’d bet it would be pretty strong.

The increased use of very hard materials accounts for part of the reason why the use of ceramic end mills is increasing, Mr. Mueller says. Nickel-based high-temperature alloys such as Inconel were formerly used only for a narrow range of aerospace-related parts. Now the range of those components in aerospace is increasing, as is the use of these alloys in other industries. And where in the past it was always low-speed, high-torque machine tools that machined these hard materials, the increased availability of machines with high spindle speed for processing this work is another factor enabling ceramic’s advance.

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?

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.

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

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

In this webinar, CloudNC Co-Founder Theo Saville reveals how U.S. machine shops are using cutting-edge AI today to accelerate their CNC machining, helping them become more efficient and save over 1,000 production hours per year. Theo will demonstrate CAM Assist, an AI solution that automates CAM programming within existing CAD/CAM platforms — and even provides working physics-based cutting parameters for your existing toolsets. Attendees will learn how the technology has developed, its current capabilities and applications, and how it is expected to progress in the near future. Agenda: How U.S. machine shops are using AI tools to automate their CAM programming and increase their productivity and efficiency How AI tools can help fill the CAM programming skills crisis What tasks AI can be successfully applied to today and what the future holds How AI can fit into machinists' workflows today without specialist training Advanced applications, such as setting cutting parameters and soft jaw fixtures with AI

All they need is speed! Tools for roughing nickel-based alloys can be used in the same processes as carbide tools, just with high rpm and no coolant.

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.

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

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.

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

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

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

Have you ever wondered whether it’s worth the time and expense to install threaded inserts into your 3D-printed projects? [Stefan] from CNC Kitchen did, and decided to answer the question once and for all, with science.

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

Plus, one more factor is improved tool manufacturing. He says, “Producing ceramic rods or other simple forms is one thing, but sintering ceramic cutting tool material and converting it into the form of a precision end mill is not easy.” Modern sintering methods make this more cost-effective. “It’s also hard to grind these tools,” he notes; “there were lessons to learn here.” Grinding ceramics is one area in which Kennametal has developed skill and techniques that are also helpful in making these tools affordable in the right applications.

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

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

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

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

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.

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.

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.

All the tools really need is speed, he says. They employ heat as part of their cutting mechanism—the heat that comes from fast, dry cutting, the same heat that might be destructive to other tools. The best performance with a ceramic end mill generally occurs in a dry machining application in the range of 3,000 to 4,000 sfm.

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

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Meanwhile, the tool is also a complement to carbide, he says. Carbide tools are still needed. While ceramic wears much more slowly than carbide in hard materials, it does wear. Indeed, the ceramic tool wears gradually, doing so all the while it is cutting, so that the cutting edge is slowly and constantly changing. The end of the ceramic tool’s life comes only when the edge has entirely eroded away.

We enjoyed seeing [Stefan]’s tests, and appreciate the data that can help us be informed consumers. [John] over at Project Farm does similar head-to-head tests, like this test of different epoxy adhesives.

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

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.

Why so cross? - tungsten carbide insert definition

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