(PDF) A Review on Tool Life in Coal Measures Rocks - carbide insert drills

 2024-07-08 06:21:30

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.

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

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.

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.

Surface measurement is becoming increasingly important to ensure proper performance of a manufactured product. Advanced surface measurement tools are not only beneficial in the manufacturing industry but also have unconventional applications.

Pairing automation with air-driven motors that push cutting tool speeds up to 65,000 RPM with no duty cycle can dramatically improve throughput and improve finishing.

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.

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

Consistency is key for beryllium manufacturing, so the data visibility granted by Harmoni has swiftly become a vital, profitable tool in the shop’s arsenal.

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.

Moving from cut tapping to form tapping for a notable application cut tooling costs at Siemens Energy and increased tool life a hundredfold.

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.

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

Before switching to ceramics, TNG used carbide inserts to produce two API ring grooves on 31/8-inch-diameter valve bodies with a 1963 manual-engine lathe, a process that took between 10 and 15 minutes each to complete. The real challenge, though, was in reconditioning these valve bodies, because it often required cutting through difficult-to-machine materials such as Inconel. For instance, after opening the grooves in the cast steel base material 3/16-inch larger than the API specifications, the valve went to the welding department for Inconel cladding. From there, the process involved opening a straight face groove with a face grooving tool followed by an API ring groove tool. This was only possible by moving into the cut 0.100-inch axially, then moving in a positive and negative radial direction to the groove’s full width. After that, the machinist would move the tool in another 0.050 inch and blend from side to side to match the width of the previous radial cut. These tiny increments were repeated until the full depth of cut was reached. An experienced, efficient machinist like TNG’s lead machinist, Cimaron Hylton, could produce one groove in about 45 minutes, though many days it took closer to an hour.

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

Given the productivity gains for just one valve feature, Mr. Hylton has no question about moving forward using ceramic inserts. TNG is even planning on producing two valves per week in the future because of these improvements.

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

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.

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.

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.

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.

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

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

Another problem was the machine’s low speed. It simply didn’t have the torque necessary to efficiently machine all layers of the material, and it would rumble and beat everything up, Mr. Hylton says. He often used three carbide insert tips during the process, requiring him to stop, pull the insert, change it and hit cycle start again. The entire grooving process took between 47 minutes to an hour to complete. To make matters worse, Mr. Hylton says that sometimes the insert would break randomly; there was no consistency at all.

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

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

Now add a firecracker into the chamber, load the gun, and insert your fuse. Aim the gun, light the fuse, and stand back!

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.

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

The groove is produced in one shot, eliminating the finish pass as well. When TNG started using the ceramic face grooving tool, Mr. Hylton says he was nervous. He questioned his Greenleaf representative about his suggested cutting speeds. However, he says his fears were soon calmed when he saw the Stellite coming off like powder. The ceramic face grooving tool can cut the groove in 30 to 40 seconds.

TNG also uses ceramic inserts on its bread and butter work of cutting valve seats in 410 stainless with a Stellite overlay. According to Mr. Hylton, this application is tricky because the groove goes through the Stellite, then through the heat-affected zone and down to the base material—an application that requires cutting material ranging from 40 to 67 HRC.

While manufacturing parts just in time (JIT) has many advantages for a shop’s customer, shops oftentimes face challenges with this sort of production schedule. Namely, there’s no wiggle room for meeting deadlines.

Cut the length of metal to size and shape as needed. With that done, mark the position of the wheel axles, and core a hole through the metal as needed.

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 ceramic inserts really show their colors during the reconditioning applications, Mr. Hylton says. After the Inconel cladding is applied, he mills down the weld that’s bulging above the flange and follows up with the Ring Max tool, cutting the ring groove in just 28 seconds. Because ring groove machining is a continuous cut, through-spindle coolant is used. The coolant is used not to cool the insert, but to cause the chips to become more brittle and break into smaller pieces, sometimes becoming almost powder-like.

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.

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.

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

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

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."

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

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

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

Attach the elevator to the rear of the carriage and wheel mount to the front. Then mount the barrel to the top of the carriage. With that done, mount the wheel to the gun carriage as needed.

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.

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

With that done, take the barrel of the cannon and flatten off the part of the barrel that will contain the chamber. Next, bore a hole from the flattened part into the bore of the barrel, and thread it. This will be used to mount the gun to the carriage.

Each valve body features two ring grooves. These features alone would’ve taken two hours to produce on the manual engine lathe during reconditioning applications.

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

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

With that done, mock up the position of the wheels against the gun barrel. Using another length of metal, sketch out the design of the gun carriage.

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

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

Add padding to the rounds as needed to fit snuggly in the barrel. With that done, your mini cannon is now complete.

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

Spurred by often unpredictable tool life and lengthy production times, TNG turned to ceramic inserts from Greenleaf. In the ring groove application, the company decided to use the Ring Max API ring groove cutter with WG-300 whisker-reinforced ceramic inserts. Designed specifically for the oil and gas industry, Greenleaf’s Ring Max line of ring groove tooling is engineered to reduce the machining time of API ring grooves, while the basic concept of WG-300 involves reinforcing a hard ceramic matrix with extremely strong, stiff, silicon-carbide crystals, or “whiskers.” The whiskers are dispersed into a matrix of fine-grained aluminum oxide, where they act much like glass filaments do in fiberglass, for example, by adding tensile strength and improving the fracture toughness of the brittle matrix.

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.

Mastercam 2025 incorporates big advancements and small — all based on customer feedback and the company’s commitment to keeping its signature product best in class.

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.

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.

If you enjoyed this project, you might enjoy making some more firearm-related projects? How about, for example, your own working cardboard gun?

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

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

This will take some time, but you can make the design however you’d like. However, try to make the barrel thicker towards the middle (or where the chamber will be) and more splayed towards the end of the muzzle. You can refine the shape using files, were needed, too.

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

The first step is to take the metal for your barrel and place it in your lathe. Turn the metal to make the basic shape for the barrel of the cannon.

TNG Energy Services Inc. was experiencing inconsistent carbide insert life in valve grooving applications. Greenleaf's Ring Max and face grooving tooling helped to reduce production time and increase reliability.

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

Mr. Hylton says he’s noticed the Xsytin-1 grade shows significantly less damage when the groove is complete, so he plans to transition the Ring Max application to the new insert grade once he runs through his batch of WG-300.

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

Using Greenleaf’s Ring Max API ring groove cutter with WG-300 whisker-reinforced ceramic inserts helped TNG reduce the time it took to cut one ring groove from about 45 minutes to just 28 seconds.

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

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.

TNG’s most common work is cutting valve seats in 410 stainless with a Stellite overlay. A face grooving tool with Greenleaf’s new Xsytin-1 ceramic inserts and a support blade help cut through all layers in this application.

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.

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

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.

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.

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

The Diatool Top Speed Disc features a solid reamer body with multiple connections to produce tolerance stack up.

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

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!

With the carbide inserts, Mr. Hylton says he had to peck at 0.005-inch depth increments to keep any edge at all. In addition, the retract amount that was programmed into the peck cycle had to be larger than usual due to tremendous amounts of tool pressure. In this case, the actual surface of the cutting tool/workpiece interface was 0.010-inch farther out than the actual machine position. The need to have a 0.012-inch buffer between pecks increased the actual feed travel to 1.498 inches. This meant the machine had to feed a total of six times the actual depth of the groove. The slow nature of this process was exacerbated by the need to peck.

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.

Next, make some ammunition for the gun using small lengths of wood. Shape into ball or bullet shapes as needed.

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

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.

According to Mr. Hylton, taking such small depths of cut was necessary to reduce vibration and chatter, yet it didn’t fully eliminate it. Several times during the grooving process, machinists had to check the pitch diameter to ensure accuracy. They also had to hand-polish the angled groove walls.

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

Mark out six equidistant points around the middle of the wheels. With that done, core out the points to make some openings in the wheels.

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

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

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.

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

Although WG-300 is designed for excellent shock and wear resistance at high surface speeds for nickel- and cobalt-based superalloys, the grade is a good match for TNG’s application, which runs the materials at a relatively modest horsepower rating (20 hp) on its Hwacheon Vesta 1050B CNC mill.

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.

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

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

Next, take your Perma blue and coat the gun carriage parts as needed. With that done, rig up a barrel elevator mechanism for the rear of the gun carriage.

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.

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

Then machine the wheels of the cannon to your liking. Once happy, bore a hole through the center of each wheel so they can be mounted to an axle.

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

Pairing a shoulder mill with a five-axis machine has cut costs and cycle times for one of TTI Machine’s parts, enabling it to support a niche racing community.

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

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.

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.

Now, Mr. Hylton says the problem is the base material. “Before, I couldn’t wait to get there,” he says. “Now, when I hit the stainless, the chips come off in long strings. The inserts get a little beat up on the sides from the chips because face grooving is a nasty operation.”

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

With the main barrel more or less complete, we can now machine the wheels. Take a disk of metal and place it in the lathe.

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.

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

The Inconel cladding that bulges above the valve flange is later milled down and then cut with the Ring Max tool during reconditioning applications. The ring groove is cut in just 28 seconds.

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.

Cannons are impressive pieces of kit, but they tend to be pretty big, and frankly dangerous things to have at home. So, why not make a little toy one?

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

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.

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.

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).

Diagnosing when a tool is failing is important because it sets an expectation and a benchmark for improvements. Finding out why gives us a clue for how to fix it.

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.

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

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

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

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

With the basic components of the cannon now done, we can begin to add some decorative features to it. Let’s start with the wheels.

With the main design for the barrel complete, the next step is to create the bore of the barrel. Turn the barrel around in the lathe, and core out the barrel of the cannon as needed.

This was especially true for TNG Energy Services Inc., a geothermal company that provides both equipment and services from its Bakersfield, California, headquarters. The company’s mostly JIT workload along with meeting strict quality control requirements led its employees to work large amounts of overtime. This was due, in large part, to the challenges of machining grooves in valve components for oilfield applications using conventional carbide inserts. By switching to ceramic inserts from Greenleaf Corp. (Saegertown, Pennsylvania), TNG was able to dramatically reduce cycle time for two valve applications, meeting deadlines without the additional overtime costs.

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?

While the ceramic inserts could potentially be used for more than one groove, he says that he changes them after each groove to be on the safe side. But even at one groove per insert, he says he’s impressed with the predictability and longevity of the ceramic inserts. In fact, he’s quit trying to push tool life in the face grooving operation because the ceramic inserts are comparable in price to the carbide inserts when time savings are factored in.

Now, the company uses a face grooving tool with Greenleaf’s new Xsytin-1 ceramic inserts and a support blade. According to Greenleaf, Xsytin-1 is a phase-toughened ceramic insert grade that is showing promise for a wider range of materials than traditional ceramic insert technology, bridging the gap between conventional carbide and ceramic inserts for exotic materials, as well as more conventional metals such as mild and stainless steels. The company says its proprietary phase-toughening ceramic manufacturing process developed for this coating-free grade results in predictable, wear- and thermal-shock-resistant inserts that are twice as strong as the company’s WG-300 whisker grade. It also enables the generation of a sharper insert edge, which can lead to reduced tool pressure and better surface finishes.

(PDF) A Review on Tool Life in Coal Measures Rocks - carbide insert drills

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