Rego-Fix Tool, meanwhile, recently expanded its retrofit reCool coolant through system. Previously matched with live tooling on CNC lathes, the system can be now be used with static toolholders on Swiss automatic machines.

WEST BOYLSTON, MA – EMUGE-FRANKEN USA, a leading manufacturer of high-performance taps, thread mills, end mills, drills, and other rotary tools, has introduced a significantly expanded line of Thread Mills, including innovative solutions for challenging threading applications and materials such as nickel alloys, titanium, high tensile strength steels, hardened high alloy steels, cast iron, cast aluminum and more. EMUGE-FRANKEN offers manufacturers a wide breadth of tooling options and industry-leading designs with five distinct thread mill tool families to address a range of machining requirements.

“In Swiss applications where the parts and work envelope are generally smaller, through coolant when and where available is always a better option than relying on flood coolant,” says Garfield.

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“Most Swiss machines just use flood coolant [and have] a little stick out there shooting the oil where you’re cutting. That may or may not be an accurate way of getting [coolant] there. [The reCool system] brings the coolant in through the nut, and now you can go through your cutting tool, something that’s always been hard to do with a Swiss machine,” says David McHenry, engineering and technical manager at Rego-Fix Tool.

“There are many tools that were designed with the Swiss machine in mind, due to the limited tooling space and stations,” says Douglas Paoletta, president and owner, Encompass Swiss Consulting in Richmond Heights, Ohio. “Iscar’s Pentacut insert, which is a five-sided indexable tool, is one. One of the first ‘back turning’ tools, and still one of the best, is the Kyocera ABS/ABW series tool. Kennametal has one of the best ‘quick change series’ tools called the KM Micro,” adds Paoletta, whose company offers on-site training for shops and manufacturers interested in Swiss-type machining.

Horn, among other cutting tool companies, has new offerings for the Swiss-type turning sector. “Although Horn has traditionally been oriented towards small part Swiss type machining, we have introduced new tooling dedicated to Swiss-type turning grooving and milling applications. A recent introduction to our existing 274 line was the System 274 ‘µ’ finish for micro turning, grooving and back turning. In addition, our Graf line of Swiss tooling offer numerous options for holding with round shank holders and height adjustable quick change holders for most Swiss type machines, i.e. Star, Miyano and Citizen,” says Garfield.

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“Coolant delivery can be the key to success and direct delivery via coolant nozzles built into the tools can have benefits of better chip control and cooling of the component and chips,” says Kevin Burton, product specialist at Sandvik Coromant in Mississauga, Ontario.

EMUGE-FRANKEN USA is a wholly-owned subsidiary of the 1,950 employee German company EMUGE-Werk Richard Glimpel GmbH & Co. KG (Lauf, Germany). EMUGE-FRANKEN USA offers end-user technical support through a network of in-the-field engineers and in-house product specialists, all with extensive tooling and application experience. Over 10,000 types of cutting tools and accessories are stocked in the company’s U.S. and Canadian headquarters located in West Boylston, MA, U.S.A. The recently expanded 50,000+ sq. ft. facility includes a technology center with a machining and tooling demonstration showroom and classroom, tool manufacturing and coating, reconditioning, warehouse, sales, support, and administrative offices.

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A comprehensive 44-page EMUGE Thread Milling Product Guide is available that provides details and specifications about the broad and expanded line, illustrated with vivid applications photography, tool pictures and technical drawings. Included in the Guide are product descriptions, recommended feeds and speeds, and application and materials data.

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“Typically PVD coatings or uncoated tools are used for Swiss-type turning operations,” says Ludeking. “These provide the sharpest cutting edges, thereby reducing forces on the small workpieces. Also, these tools have higher edge toughness that helps them withstand the high forces generated when cutting at low speeds often encountered in small diameter components. Because CVD coatings require somewhat larger edge-rounding (hones), they tend to generate higher cutting forces that are detrimental to small components. On the positive side, new CVD coating technology is enabling smaller hones, making them good choices for higher speed operations or very abrasive alloys,” he adds.

“Manufacturers have really paid attention to the growing market and needs of the Swiss turn industry, so there really is a lot available [that meets] the needs of the Swiss-type turn shops,” he continues. “Considerations in tooling must also be made in relation to the geometry of the part and a possible non-standard program format to create certain part features. Some Swiss machines are limited on stick tool stations. There are many new tools out there that combine several things like face, turn, groove for the O.D. or drill, bore, and thread for the I.D. By using these combinations we can free up tool stations allowing us to machine more complex or tooling intensive parts with the limited stations.”

“To improve productivity and profitability in the most challenging threading applications, we are pleased to offer a significantly broadened line of new and unique thread mills,” said Mr. Marlon Blandon. “The science of thread milling is constantly progressing to efficiently machine tougher, higher cost materials and complex parts, and EMUGE-FRANKEN is continually innovating to meet the latest needs.”

“The H.P increases the tool life and reduces the need for intervention by the operator for chips wrapping on a part.

“Swiss machines have three work holding devices in them if you don’t include the bar feed collets. The headstock collet, the guide bushing (which is what the stock feeds through during the cutting and is used for support), and the pickoff or sub-spindle collet which takes a parted-off work piece and can hold it for secondary operations on the sub spindle side of the machine.

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The new Walter Cut G1011-P grooving tool from Walter USA, which can be used in Swiss-type turning, is internally cooled. “The G1011-P is designed so the coolant stream is released very close to the cutting edge, guaranteeing the best possible effect of the coolant, no matter what the supply pressure is,” says Kurt Ludeking, product manager of turning at Walter USA. “Compared to an external coolant supply, this ensures coolant at the cutting edge throughout the cut, especially important in deep, narrow grooves and parting operations

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Industry experts were also asked about grades and geometries for Swiss-type turning tools. “A grade specifically for use in Swiss-type turning is WSM21, a mono-layer PVD coating that is designed to withstand the low cutting speeds often encountered with small diameter components. Grades with thinner PVD coatings and sharp edges are generally best,” says Ludeking. “Although there aren’t any specific Swiss-turning geometries, those with aggressive chip control for light feed rates and depth-of-cut are often best for Swiss-type operations.”

There’s a general consensus that when it comes to designing tooling for Swiss-type turning, coolant through is preferable to flood coolant. Coolant through tools utilize high pressure (H.P.) for delivery.

EMUGE-FRANKEN tooling experts are available to help guide manufacturers through the tool selection process. For additional tool application resources and to download the free EMUGE Thread Mils Product Guide visit here.

GenSwiss’ recently released its Ti-Loc SwissClamp System “for rotary tooling in Swiss machines … it can be used for milling and slitting operations that utilize ER collets for tool holding,” explains Laprade.

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Insert shape also plays a big role in Swiss-type turning “since we normally do not rough and finish turn parts. Parts that have undercuts, larger grooves, angles into smaller diameters, and other features like that, are studied to see if a different tool can provide the entire profile in one turn. If not then we have to look at segmenting the part into sections to process,” says Paoletta.

For over 100 years, the German company group EMUGE-FRANKEN has been one of the world’s leading manufacturers of precision tools for thread cutting, drilling, gaging, clamping, and milling. With 1,950 employees, EMUGE-FRANKEN offers an innovative product program with 40,000 in-stock items and a multiple of that with customer-specific tools. The product range focuses on applications in the automotive industry, power plants, aerospace industry and medical technology as well as general manufacturing. As a complete system supplier for the machining industry, EMUGE-FRANKEN has branch offices or sales partners in 52 countries.

The opinions expressed in this news release are the author’s only and do not necessarily reflect those of Medical Design & Outsourcing or its employees.

“Each of these devices can be ordered with special options that might pertain to the application being performed. Special ID tolerances, extended nose lengths, extended land surface, over gripping geometry, or special ID shapes are all things that can be modified on a guide bushing or pickoff collet,” says Scott Laprade, marketing manager, Genevieve Swiss Industries, Inc.

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To sum up, Laprade cites an old retail truism. “Swiss tooling is a very ‘get what you pay for’ type of product. When you’re trying to continuously ‘split tenths’ you want something that is high quality and more importantly, repeats each time a job is set up or when a tool is changed. A good tool or tooling system will eliminate the need for an operator to chase a tolerance because the tooling wasn’t intended for it or is poor quality,” notes Laprade.

“At GenSwiss we recommend micro-thin PVD coatings that don’t change the edge conditions of the cutting tools when applied to them,” adds Scott Laprade, marketing manager, Genevieve Swiss Industries, Inc. (GenSwiss). “When working with small diameter parts you want the edges to remain as sharp as possible to prevent pressure build up which can lead to deflection of the work piece. Some coatings and processes deposit a ‘bead’ of coating on the edge of the insert which can round it off by up to a thousandth of an inch.”

“Maximizing the envelope is crucial given the tooling requirement to complete a part versus space provided,” adds Jim Garfield, regional sales manager, at Horn USA. “Swiss type multi-function tools can reduce the number of tools/holders required as well as reduce cycle times. Quick-change Swiss holders can reduce downtime when changeover is necessary due to tool wear or new part set up. Repeatability of center height when changing insert/tools is of utmost importance,” he adds.

“On the I.D, using coolant-through drills for instance, can gain you a 2x feedrate over a standard carbide drill or 3x to 4x a cobalt drill, while you can also increase your SFM for the tool,” he explains.

“PVD coatings are most common due to the reduced heat factor in small part machining—small contact diameter, lighter feeds and good cooling. The required sharper cutting edges also dictate that PVD be used,” echoes Burton.

“Decoflex is a modular tooling system specifically designed for Swiss turning head stock machines…we have introduced a multi-headed collet chuck that will work in both directions of the spindle simultaneously,” says Scott Leitch, marketing manager with Exsys.

“When turning the O.D. of a part, H.P. coolant pays big dividends on gummy/hard materials or long cuts where stringy chips are a problem,” says Paoletta.

When the question is about the best kind of coatings on Swiss-type turn tooling, there’s further consensus.

Exsys Tool places its expertise with tooling for Swiss-type machines front and center. The company highlights its Decoflex tooling system for interchangeable tools.

As Swiss-type turning edges towards the mainstream, cutting tool companies continue to provide a steady stream of appropriate tools. Such tools have to be able to function in the confined work envelope characteristic of Swiss-type machines.

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