A New Spin on CNC Machining Face Grooves - grooving insert sizes

 2024-07-02 08:13:42

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.

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.

MCC Tooling makes and resharpens custom cutting tools, step drills, form tools and dovetail cutters in quantities ranging from one to as many as 100 pieces for customers in the oil, airline and medical industries. Marcus Alexander founded MCC Tooling in 1984 in the Dallas suburb of Garland, Texas, with leased space and a single grinder. The company has since grown into a 10-person business with a variety of machines, including 17 grinders working with carbide, stainless steel and high speed steel parts.

An example of a part machined with the Mitsubishi MV1200-R with B axis and Esprit. This custom broach required a special radius in the corner of the part.

Babcock International Group (Babcock), the defence company, has been awarded a two-year contract extension by the UK Ministry of Defence (MOD) to continue to provide technical support services across the UK armed forces.

Tooling manufacturer, Horn has introduced a new carbide insert grade, SG66, for turning components from steel that has been case hardened to 58 HRC.

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.

Marcus Alexander, owner of MCC Tooling near Dallas, Texas, runs his shop's Mitsubishi MVR1200-R wire EDM machine with MMK Matsumoto B axis. The shop used Esprit’s simulation capabilities to get up to speed on its operation more quickly, saving time and eliminating the potential for scrapping a lot of parts in the process.

Ceratizit USA has promoted Troy Wilt from national sales manager to managing director of Ceratizit USA, cutting tools division.

Differential gaging measures using two devices, which has advantages over standard, comparative measurements using a single sensing head. These include the ability to measure size without regard to position.

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

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.

Grant funding for workforce training or the purchase of new equipment is an undervalued but complex resource for machine shops. We enlisted an expert to help navigate the process.

In 2013, Esprit helped the shop move to a Mitsubishi MV1200-R with B axis, which Mr. Alexander purchased because it could hold closer tolerances than the FX 10. While learning how to program it, MCC machinists initially resorted to trial and error. Esprit’s software simulation enabled them to take this exploratory approach without severe consequences. As Mr. Alexander tells it, a major benefit of the software was the ability to see the heads moving on the software’s simulation before running the part program on the EDM itself. This ability reduced the time wasted by running a potentially incorrect part and also avoided scrapping parts in the process. In the end, Esprit helped MCC get up to speed quickly with the machine. Now, it takes less than two minutes to set up the B-axis EDM.

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.

Dimensional accuracy, stability and process reliability are assured, as the torque generated during machining is dissipated into the body. Horn offers two body types, the first having a cutting edge diameter of 100mm. It is equipped with 14 type 406 indexable inserts, which produce seven effective cuts ranging from 9.6mm to a maximum of 12.9mm wide. Milling depth is up to 20mm. The second body type is equipped with 12 cutting inserts of type 409 and has a cutting edge diameter of 125mm. On this tool, the cutting width with six effective cuts can be adjusted between 12.9mm and 18.8mm. Maximum milling depth is 32.5mm. The successful 406 and 409 type indexable inserts have been chosen for the application. They are precision ground and achieve outstanding surface quality at the base of the groove and on the flanks. Double positive axial and radial rake angles ensure a soft cut. The tangentially screwed cutting insert's trailing chamfer produces a secondary cutting edge, resulting in outstanding machined surfaces. An additional free-form surface chamfer provides a stable wedge angle and very smooth milling. www.phorn.co.uk

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.

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.

The second body type is equipped with 12 cutting inserts of type 409 and has a cutting edge diameter of 125mm. On this tool, the cutting width with six effective cuts can be adjusted between 12.9mm and 18.8mm. Maximum milling depth is 32.5mm.

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

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

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.

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

Walter has now launched its new X·treme Evo Plus drill from the DC180 Supreme product family that is now available up to 8XD for the first time.

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.

CoroMill MS 20 is designed for repeated shoulder milling, face milling, linear and helical ramping, full slotting and plunging applications.

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

In choosing DP Technology’s Esprit CAM software to write programs for its CNC grinders and wire EDM, MCC Tooling found a CAM system so user friendly that the owner’s young grandchildren sometimes use it. More importantly, Esprit’s efficient programming saved MCC Tooling time and money getting up to speed with an advanced wire EDM and now positively impacts both machining and quoting.

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

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

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.

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.

In celebration of World Space Week, Space-Comm Expo has announced visitor registration is now officially live and open for the London ExCeL, event, running 11-12 March 2025.

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

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.

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

Software simulation helped this machine shop learn how to program its new advanced, high-tolerance wire EDM. The software also helped the shop turn job quotes around quickly.

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?

Features that save on training, programming and cycle times have enabled Speedway Motors to rapidly grow and mature its manufacturing arm.

The close connection between CAD and CAM is what links creative ideas to practical production for this unique custom manufacturer.

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

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.

The MarSurf CD 140 AF is designed to measure many different kinds of workpieces, making it suitable for a wide range of measurement tasks.

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 Boeing X-37B spaceplane is to begin executing a series of novel manoeuvres, called aerobraking, to change its orbit around Earth, the US Space Force has announced.

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.

The Mill A Groove tool can be used to cut step grooves, convex and concave radius grooves, chamfered edges, angles and special profiles with a single insert.

By investing in a 3+2-axis machine and utilizing simulation software for diagnostic checks, Techtronic Industries turned a four- to ten-week lead time into a one- to two-week lead time.

Esprit has also become a boon when it comes to job quoting. With more companies competing for projects, MCC must make sure that it provides precise job quotes quickly. “We have to know how long something will take to run in order to accurately quote a job, and we have to accurately quote a job so we don’t lose money or time while running the machine,” Mr. Alexander says. “With Esprit, after we program a job, we can produce the code and see exactly how long a job will take to run.” Mr. Alexander can draw up a print in minutes, send it to the customer and, if approved, have it running on the EDM the same day.

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.

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 first in-person IMTS in four years left the MMS editorial staff with a lot to digest. Here are a few of our takeaways from the show floor.

MCC was recently commissioned to make a double-ended tooling insert for a customer, and Mr. Alexander was able to use Esprit to draw the insert to the customer’s exact specifications and turn it into EDM code within seconds. He then used Esprit to draw a fixture that would hold a carbide blank on a CNC grinder. The job was tricky: The fixture had to be made so that the blank would locate in exactly the same spot every time on the grinders. Mr. Alexander designed a second fixture to hold the insert while he cut the form on the EDM. The process was originally supposed to take four operations, but Mr. Alexander reduced it to two using a four-axis program. Best of all, this method resulted in the ability to machine the insert in the same manner every time—Mr. Alexander can simply insert a carbide blank and go. The customer, which had searched unsuccessfully for a machine shop that could make the insert properly, was so pleased with the outcome that it now orders around 50 tools per month from MCC Tooling.

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

A new side milling cutter for stepless adjustment of groove width has been introduced by Paul Horn, and is available through the firm's UK subsidiary, Horn Cutting Tools, Ringwood. The milling body features a central sleeve that enables the required groove width to be adjusted easily on a pre-setter.

The MMK Matsumoto B axis on the EDM made indexing from tooth to tooth far more accurate. The shop cuts a lot of multiple-flute form cutters, and before the MV1200-R, making these parts required several operations on different machines as well as a longer time to set up the FX 10 EDM. Now, using Esprit, MCC can program tools in only four additional steps. The process is also very repeatable: “We can mount the tool in the B-axis EDM and walk away knowing that we’ll get the perfect tool every time,” Mr. Alexander says. Esprit also enables operators to check all the clearance and rake angles on the tools to make sure they will function correctly and that all the dimensions are correct.

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."

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

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

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

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.

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.

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.

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.

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

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

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.

Occasionally, customers come in without prints or with a tool that is so badly worn that it is almost impossible to measure correctly. Once they have an inkling of how to proceed, Mr. Alexander and his team find it easy to draw up the tool in Esprit and figure out the other dimensions. Esprit also enables MCC to more easily double-check customer measurements.

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

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

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.

Quality control supervisor and CNC programmer Michelle Steward programs a wire cutting die in Esprit software from DP Technology.

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.

MCC was able to rough-grind the broach on a grinder, then machine it on the B axis of the Mitsubishi EDM. MCC Tooling had to spade the tool and add a different size radius to each tooth at the same time without removing the tool. This job is an example of the added capabilities Esprit software has enabled for MCC Tooling.

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

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

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).

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.

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

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

MCC Tooling began using Esprit in 1999, when it purchased its first wire EDM, a Mitsubishi FX 10. “After hours of extensive research and vetting different programs and software, we felt Esprit would fit our needs and our price range perfectly,” Mr. Alexander says. “Esprit is user-friendly, works seamlessly with our machines, and it integrates well with SolidWorks. It’s so easy that my grandchildren have come here and programmed their own things for us to cut out for them.”

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.

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.

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

The successful 406 and 409 type indexable inserts have been chosen for the application. They are precision ground and achieve outstanding surface quality at the base of the groove and on the flanks. Double positive axial and radial rake angles ensure a soft cut. The tangentially screwed cutting insert's trailing chamfer produces a secondary cutting edge, resulting in outstanding machined surfaces. An additional free-form surface chamfer provides a stable wedge angle and very smooth milling.

These days, Mr. Alexander spends most of his time quoting jobs, so being able to cut down on programming and machining time with Esprit is beneficial, allowing him to spend more time completing other tasks around the shop. “Our industry is fast-paced and everyone needs a fast turnaround on jobs. Time is money for us.” And it’s clear that with Esprit, MCC Tooling is translating shorter quoting, programming and machining times into high value for its business.

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

Ceratizit USA has promoted Troy Wilt from national sales manager to managing director of Ceratizit USA, cutting tools division.

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!

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

The NeoMill-Alu-QBig indexable insert milling cutter from Mapal stands for top performance in high-volume milling of aluminium. The tool manufacturer thus offers a very economical solution for use on high-performance machines, such as those found primarily in the aerospace industry.

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

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.

As the demand for faster production cycles continues to grow, the ability to produce high-quality parts quickly and efficiently has become increasingly important. High-speed 3D printing has emerged as a key solution to reduce lead times and increase productivity across industries. However, like any advanced technology, it comes with its own set of challenges. In this webinar, Forward AM will explore both the opportunities and hurdles of adopting high-speed printing with a particular focus on overcoming those challenges. It’ll start by discussing the fundamentals of high-speed 3D printing and how it differs from conventional 3D printing methods. It’ll then move on to the key factors that influence successful implementation, including the impact of materials, equipment and design considerations. One of the main hurdles in high-speed 3D printing is ensuring the right balance between speed and part quality. Different materials behave differently under high-speed conditions — and not all equipment is optimized for this process. Forward AM will showcase some validated materials and equipment that are proven to perform well under these conditions. In addition, the presenters will look at real-world examples and applications where high-speed 3D printing has been successfully implemented, highlighting the collaboration between designers, engineers and manufacturers. By the end of this webinar, you'll not only have a clearer understanding of high-speed 3D printing with FFF but also the practical steps and considerations needed to make the most of this cutting-edge technology. Agenda: Introduction The power of high-speed printing Know the process The practical side

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

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

Reinvestment in automation has spurred KCS Advanced Machining Service’s growth from prototyping to low-and mid-volume parts. The key to its success? A young staff of talented programmers.

Dillon Manufacturing’s extra-long hard jaws feature extended reach, making them well suited for machining small diameters.

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.

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

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A New Spin on CNC Machining Face Grooves - grooving insert sizes

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