Ceramic End Mill Achieves Long Life and High MRR at Standard Machining

 2024-08-25 12:11:52

Center Speeds - end mill feed rate

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

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

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.

These precision drill bits are Bantam endorsed for use on their PCB Pro Milling Machine. Each drill bit will last for many hours of use on materials such as PCBs (lots of PCBs per bit).

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.

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

This new quick-change tooling system enables shops to get more production from their Swiss turning centers through reduced tool setup time and matches the performance of a solid tool.

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

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

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.

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.

Nonetheless, he says it is easy to understand high expectations for replaceable-tip drills like those manufactured by Allied, a specialist in holemaking tools. In the right application, the latest offerings can leave holes straight and smooth enough to make dedicated finishing tools unnecessary.

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.

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

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

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.

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

However, there is more to precise, efficient drilling than the tools themselves, particularly in holes with depth-to-diameter ratios of 9:1 or more. In a recent conversation, Mr. DeLuca outlined five recommendations for drilling deep with the company’s T-A system, a broad line of general-purpose, replaceable-tip drills designed to penetrate most steels, cast irons, high-temperature alloys and aluminum alloys.

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

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

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.

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

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

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.

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

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

In deep hole drilling, ramping immediately up to full speeds and feeds can create safety concerns and risk compromising the work. As such, many of Allied’s standard recommendations for general-purpose T-A insert drills can be summed up in one phrase: Approach the pilot hole with caution. For more specifics, see the images in the picture gallery above.

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."

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

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.

Take a look at our customer service page if you have other questions such as "do we do purchase orders" (yes!) or "are prices GST inclusive" (yes they are!). We're here to help - get in touch with us to talk shop.

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

Flat end mills are used for cutting 2D shapes like circuit boards, flat-sided 3D shapes, and for detail work. You can use these carbide end mills to cut a square edge into metal, wood, wax, and plastic.

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.

Allied’s T-A drills are available with 187 different combinations of standard insert geometries and coatings, and this is just one line of tools from one manufacturer. With so many application-specific choices available, strategies for insert drills that were once standard procedure might no longer apply.

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

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.

Barring some form of X-ray vision, chip formation is the only way to judge a drill’s performance during the cut, while there is still time to act. Curlicue shapes (that is, “sixes” and “nines”) are ideal, while longer, stringier chips carry heat away from the cutting zone less efficiently. Color matters, too. As the cutting zone over heats, chips become progressively gray, black and blue. Discolored chips can indicate the need to reduce heat by slowing spindle rpm, while stringy chips might indicate the need to increase the feed rate to a point in which machined material breaks rather than peels.

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?

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.

“Approaching a pre-existing hole cautiously helps avoid scarring or damage,” Mr. DeLuca says about these recommendations. “It allows the drill margins to engage with the material before you bring it up to speed. The hole begins to act like a bushing that keeps the drill centered and keeps parts and people safe.”

Water-soluble coolants are most common for general-purpose applications because they remove heat well. That said, semi-synthetic or fully oil-based formulations can be a better choice to improve lubricity and ensure short, segmented chips in certain cases. Although tools may wear more quickly and parameters may need to be less aggressive than with a water-based coolant, an insert coating that improves heat resistance might help compensate. It all depends on the application.

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

Pecking might be the only option if there is no time for new tools or other process adjustments. However, the result is always slower drilling. In addition, retracting the tool mid-cut can leave partially formed, undetached chips inside the hole. Carbide is wear-resistant but relatively brittle, a characteristic that can make inserts prone to premature or even catastrophic failure upon repeated contact with such a jagged, inconsistent surface. Even if inserts are not compromised, the workpiece could be. As mentioned above, most drills cut slightly oversized. “Maybe it’s only by a few thou (1 “thou” = 0.001 inch), but on some jobs, there might still be a risk of scarring the inside of the hole or cutting an oversized hole,” he explains.

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.

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.

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.

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.

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.

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There is no room in a modern production environment for climbing into workzones to mount indicators, nor for holding pieces of paper in place for tool touch-offs.

These 1/100" bits are for the finest of detail. The flat end is 0.254mm width - this level of detail is seldom required for PCB milling although is impressively available as an option.

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

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

Some batteries (such as LiPo) can't be shipped by Air. During checkout, Express Post and International Methods will not be an option if you have that type of battery in your shopping cart.

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.

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

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.

At its New Product Rollout, Ingersoll showcased a number of options for high-feed machining, demonstrating the strategy’s growing footprint in the industry.

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.

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

Core Electronics is a maker education and retail company based in Newcastle Australia. We specialise in DIY electronics, desktop manufacturing and educational technology.

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

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

Another outdated practice is the use of a 90-degree spot drill with a smaller diameter for the pilot hole. This makes sense intuitively, and, as is the case with pecking, can still be a useful rule of thumb for toolroom applications. After all, a smaller-diameter hole drilled slightly off-center is easier to correct than a larger one, while a sharp point angle helps the drill quickly and easily penetrate the part and settle into position. However, most CNC machine tools position precisely enough that the pilot drill can be the same diameter as the main drill. They are also powerful enough to drive duller points into virgin workpiece material.

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.

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

Products that weigh more than 0.5 KG may cost more than what's shown (for example, test equipment, machines, >500mL liquids, etc).

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

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

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

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

When milling PCBs, we recommend the use of 1/32" for large removal and 1/64" for fine removal. Flat End Mills are fine for PCB drill-through holes as well.

The deeper the hole, the longer the drill. The longer the drill (the greater the distance between the tool tip and the spindle nose), the greater the extent to which runout can impact results. In some deep-hole applications, the slightest wobble can wear tools prematurely and compromise both straightness and surface finish.

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

A cautious approach, modern thinking, offline presetting and attention to coolant and chips unlock the potential of the latest replaceable-tip drills for deep CNC hole-making applications.

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.

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

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

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

We deliver Australia-wide with these options (depends on the final destination - you can get a quote on the view cart page):

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.

In fact, most replaceable-tip drilling inserts feature self-centering tips with point angles shallower than 90 degrees. As a result, the insert can impact the hole’s major diameter before the self-centering point. “If you were to follow a standard spot drill with one of our tools, our drill will want to walk slightly, causing premature wear and potentially causing the tool to lead off,” Mr. DeLuca explains. “Using the same insert diameter and point angle ensures that the longer drill picks up perfectly where the spot drill left off.”

In this case, the Stealth Drill itself adds to the time-savings provided by offline presetting. This drill features an adjustable pin that moves the insert radially to mitigate the tolerance stack-up common to all replaceable-tip drills. As a result, dialing out runout no longer requires dismantling and cleaning the tool assembly, adjusting offsets, adding shims to tool turrets, or relying on experienced machinists to attempt an unorthodox solution.

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.

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

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“As much as our customers want it to be a finisher, a drill is still a roughing tool,” says Salvatore DeLuca, product manager at Allied Machine and Engineering. “It’s always going to cut slightly oversized.”

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.

In addition to saving time, making drill margins easier to find and measure prevents costly mistakes. “In my opinion, the ease of setup alone is worth the investment,” Mr. DeLuca says. “When you look at the reduction in setup cost and machine downtime due to incorrect setup measurements, it’s hard to imagine not having a presetter.”

One non-negotiable factor is the use of through-coolant drills. Machine tools must also deliver sufficient coolant pressure. Small drills require significantly more pressure for chip evacuation to keep up with material removal because they must run at higher rpm to achieve the same surface speed as larger tools. “The greater the pressure, the faster the chips come out of the hole, and the faster you can spin the drill,” Mr. DeLuca says.

Other problems can be easier to overlook. “One of the most underestimated inputs in any machining process, even beyond drilling, is the coolant,” Mr. DeLuca says. Given the significant impact of coolant on how chips form, adjusting coolant concentration and flow can also help address problems with discolored “birds’ nests.”

One example is pecking. Periodically reversing the tool’s feed during the cut should not be required to ensure chips evacuate from the hole. “When you see pecking these days, it’s usually someone misapplying a tool or using the wrong tool entirely,” Mr. DeLuca says.

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

However, the need for careful setup is no excuse to spend inordinate amounts of time identifying and correcting for runout with every tool or insert change. More specifically, there is no room in a modern production environment for climbing into workzones to mount indicators, nor for holding pieces of paper in place for tool touch-offs. Chances are, assembling tools offline with a presetter will save significant amounts of time in any deep-hole drilling operation.

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.

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.

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.

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.

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!

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.

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

At one customer’s facility, three of Allied Machine’s replaceable-tip, self-guided “Stealth” drills (so named for their quiet operation) are set up in the toolroom at the beginning of each shift. This process takes less than 10 minutes. In contrast, setting up three tools on the machining line could take as long as 30 minutes, amounting to 90 minutes of lost time over the course of three shifts. In a 24/7 production environment, that adds up to nearly 2,200 hours per year (a figure that does not account for machine downtime during tool changes). “A presetter is probably 5% of the cost of those lost hours,” Mr. DeLuca notes.

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).

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.

Ceramic End Mill Achieves Long Life and High MRR at Standard Machining

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