Empirically speaking, Keshavan says, Rz is equal to about 7 to 10 times Ra. To target 0.2 µm Ra, he says Rz would be at least 1.4 µm and out of print.

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.

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.

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 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

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!

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.

The different ways we measure surface finish come with fine distinctions, says Keshavan. Roughness average (Ra) is a parameter commonly used to measure surface finish, but he argues that Ra does not provide a full picture. In particular, the parameter does not make a distinction between peak and valley parameters. For instance, a part with five distinct valleys of the same depth could have the same Ra as a part with five distinct peaks of the same height. Considering Ra alone, the finishes of these parts are the same. That is why, in certain applications, other parameters will be more appropriate to call out for the surface finish measurement.

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

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.

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.

Honing is typically performed to bring bores to a precise size or achieve a specific surface finish. Here, a leading honing equipment manufacturer answers a few commonly asked questions about this process.

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

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

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

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.

One of superfinishing’s main benefits is that it is a cold material process, which means it eliminates the thermally damaged layer that is left by previous operations such as grinding. This has a key impact on extending component life. For example, Keshavan says that if the bearing surfaces of an engine crankshaft or camshaft were not superfinished, component stress and wear could lead the engine to break down every 20,000-30,000 miles instead of the 200,000-300,000 miles as is common for today’s engines.

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.

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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.

So, how does superfinishing remove stock without the heat that is so typical of abrasive machining? The answer has to do with depths of cut. “When you turn or grind a part, the depths of cut could range from 50-100 microns or higher,” Keshavan says. “Removing that amount of material in a short amount of time requires lot of energy, and the part heats up. Superfinishing removes 1-2 microns of stock on radius and requires less energy.”

While manufacturers often use various finishing process terms interchangeably, Keshavan says each process has a subtle nuance that may make it better suited for a particular application. Here are some common finishing processes to compare:

If you want to streamline production and be competitive in the industry, you will need far more than a standard three-axis CNC mill or two-axis CNC lathe and a few measuring tools.

Keshavan recommends referencing the ANSI/ASME B 46.1 national surface texture standard. It lists 100 or more parameters that can be used to measure finish, just a few of which are Ra, reduced peak height (Rpk), reduced valley height (Rvk), bearing area ratio (Tp), and the average distance between the five highest peaks and the five lowest valleys in a sampling length (Rz).

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.

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 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.

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.

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

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.

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.

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.

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."

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

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

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?

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

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

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

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

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

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.

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.

Determining which finishing process to use depends on the end use of the part. Keshavan says, “Polishing is best suited for applications in which part geometry is not critical and aesthetics are the main concern; superfinishing is best suited for mission-critical parts.”

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.

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

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.

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

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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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

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

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

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

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

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.

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.

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

Despite its usefulness for automotive parts, the application potential for superfinishing is wide-reaching. From job shops to large original equipment manufacturers (OEMs), superfinishing has found roles in small medical parts such as hip and spine implants and aerospace parts such as turbine and landing gear components. According to Keshavan, superfinishing can conceivably be used in any OD application that requires the precise removal of small amounts of stock on the order of 0.002-0.005 mm from the diameter. While steel is the most common material to superfinish, he says, the process can also be applied to exotic alloys, titanium, aluminum and even glass and ceramic.

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

Another common problem he sees is applying a blanket process capability index (Cpk) without paying attention to tolerancing, particularly given upper and lower bounds on surface roughness. For example, consider another print specification:

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 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.

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

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.

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).

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

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

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

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

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.

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.

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.

Learn what superfinishing is, what applications it should be used for and why you should take care when specifying surface finish parameters.

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.

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

The key to excellence in superfinishing operations is the incoming grinding finish on the workpieces. With the right start, superfinishing is a very effective and economical process for achieving mirror-like finishes.

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.

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.

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

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.

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“If a Cpk of 1.67 or better is demanded on all the parameters, we need to be at roughly 50% of the tolerance, so we shoot for 0.5 Rz,” he says. “If we were to do that, Ra could be less than 0.05 µm, which is out of spec. If we were to target Ra to hit the Cpk, Rz would be pushed toward the higher end of the spec or out of spec altogether. This is why it is extremely important to tolerance this correctly.”

There is a constant pressure on manufacturers to both enhance the efficiency of manufacturing and enhance the performance of manufactured products, often by taking the weight out of components. For automotive manufacturers, this is coupled with pressure to reduce emissions. According to Sanjai Keshavan, manager of the ECO Hone and Microfinishing Systems Division of Nagel Precision Inc., all these pressures helped lead to the development of superfinishing — a finishing process first applied to production around the 1930s that is designed to enhance a component’s surface finish while also improving its micro-contour accuracy through improved roundness, straightness, cylindricity and more.

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

Nagel's ECO 40 hone and SPV clamp bore face grinder helped Global Gear and Machining to produce gears with stringent bore-to-face perpendicularity tolerance.

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.

“If these parameters are judiciously selected and toleranced correctly,” he says, “they permit manufacturing engineers to choose the most efficient way to process the parts and maintain the product’s integrity.”

The C 1100H is a heavy-duty flatbed lathe built with a monoblock cast iron bed that absorbs machining efforts and vibration, making it highly rigid, stable and accurate.

Both superfinishing and polishing are used to create a fine surface on outside diameters. Polishing is a more flexible process because a brush, a lapping compound or a vibratory process like tumbling can all be used. Tumbling makes it possible to polish many parts at once. In contrast, superfinishing uses a fixed abrasive to impart the finish, and only one part is finished at a time. Keshavan says superfinishing has advanced beyond hard tooling. To add more flexibility to the superfinishing process, his own company, Nagel, has developed what it calls “D-flex” band technology that acts like a fixed abrasive but can flex to compensate for as much as a 15 mm change in diameter.

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

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."

He says problems arise when multiple parameters are specified without regard to their feasibility given the other specified parameters. Consider the following print callouts:

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.

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

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.

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.

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.

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.

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

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.