Better, Faster, Smarter - long reach carbide end mills

“The problem with that is it would take a giant round insert to be able to take a reasonable depth of cut,” he said.

Dimension that defines the exterior diameter of a cylindrical or round part. See ID, inner diameter.

The Walter Turn toolholder features rake-face cooling to help break and control chips, and double flank-face cooling directly at the cutting edge to extend tool life.

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.

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."

Carlile said Iscar furnishes cutters with a variety of lead angles to enable different chip thinning capabilities. The lead goes down to 9 degrees with the Mill4Feed line while a newer offering, the Logiq4Feed, has a 17-degree lead for reduced chip thinning.

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

Bokram said the more robust geometry permits the double-sided inserts to have an expanded range of applications beyond finishing, including medium and roughing operations, as well as machining heat-resistant superalloys and titanium.

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.

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

“It completely eliminates that micro back lift we have on the opposite side of the business end,” he said.

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

As indexable inserts evolve over time, so does a toolmaker’s relationship with its customers — sometimes fairly abruptly. Jan Andersson at YG-1 Tool (USA) said there’s been a paradigm shift over the past decade or so in how tool suppliers interact with customers as the metalcutting sector has transitioned from having one manufacturing engineer per production line or work cell and all machines being run by machinists to having one manufacturing engineer overseeing the facility as machine operators replace machinists.

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

“For instance,” he said, “we can lay an insert negatively in the pocket with an additional dovetail to make a very strong, robust mount but still have enough carbide so that we can bring the cutting edge positive and have a positive clearance underneath.”

Process of generating a sufficient number of positioning commands for the servomotors driving the machine tool so the path of the tool closely approximates the ideal path. See CNC, computer numerical control; NC, numerical control.

“It’s detrimental from a technical perspective,” he said. “The one thing about double-sided inserts is you risk damaging the noncutting edge. If you don’t have chip control, the chip can wrap around and damage the bottom side of that insert.”

He said the ENMX09 is 6.2 mm (0.244") thick, which compares with insert thicknesses of 4.6 mm (0.181") and 4.8 mm (0.189") for two popular competing products.

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

Metal-removing edge on the face of a cutter that travels in a plane perpendicular to the axis. It is the edge that sweeps the machined surface. The flat should be as wide as the feed per revolution of the cutter. This allows any given insert to wipe the entire workpiece surface and impart a fine surface finish at a high feed rate.

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.

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

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.

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.

For more information from Iscar USA about its high-feed indexable insert milling tools, view a video presentation at cteplus.delivr.com/2swtt

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

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.

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.

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.

Carlile said cutting with a round insert generally generates chips that are too thin to absorb enough heat, with the remainder going into the part and tool.

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

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

TungAluMill is designed for efficient machining of aluminum alloys and other non-ferrous materials at high speeds.

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

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

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

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

Form of milling that produces a flat surface generally at right angles to the rotating axis of a cutter having teeth or inserts both on its periphery and on its end face.

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.

Andersson said YG-1 Tool’s high-feed cutter has a 10-degree lead angle, which directs almost all the cutting forces into the spindle.

Tungaloy has introduced ten new XVCT-AM square shoulder milling inserts to expand its TungAluMill line designed for non-ferrous applications.

The movement away from rough milling with round inserts to high-feed milling reduced the required size and number of cutters, as well as the size of the remaining corner scallop, he said.

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.

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

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.

Replaceable tool that clamps into a tool body, drill, mill or other cutter body designed to accommodate inserts. Most inserts are made of cemented carbide. Often they are coated with a hard material. Other insert materials are ceramic, cermet, polycrystalline cubic boron nitride and polycrystalline diamond. The insert is used until dull, then indexed, or turned, to expose a fresh cutting edge. When the entire insert is dull, it is usually discarded. Some inserts can be resharpened.

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

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

In addition, Romlin said rough milling with a round insert limits the ability of the tool to machine a shoulder, leaving a large scallop to be removed in a subsequent operation. He said the strategy for roughing with round inserts often involved starting with a large cutter and following with maybe two smaller inserts to rough a part.

“Traditionally, manufacturing engineers were not only designing and setting up new components and new production lines, but they were also working on continuous improvement,” he said. “But if you have one manufacturing engineer for the plant, there is no time for continuous improvement. That time is spent being a firefighter.”

Andersson said one issue for high-feed cutters results from users’ perception of the capabilities of the 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.

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.

Threading tools with the flexibility to thread a broad variety of holes provide the agility many shops need to stay competitive. They may be the only solution for many difficult materials.

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

For example, Seco Tools introduced the High Feed Square Cut size 14 milling system late last year. The toolmaker reports that the single-sided, straight-edge insert geometries of the system are suitable for high-feed ramping, pocketing, plunging, facemilling and copy milling.

“When it comes to cost per part, it all comes down to productivity because in reality the cost of the insert is very little in the scope of things,” Andersson said, adding that the cost of cutting tools represents on average 3% to 5% of total production costs. “You drive down production cost through productivity.”

Built on the features of the conventional XVCT-AJ inserts, the new XVCT-AM inserts introduce an enhanced interface design. This design improves insert retention during high-speed machining while reducing raw material usage for insert production, all without compromising cutting performance.

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

In response, cutting tool manufacturers had to focus on developing products that deliver a high level of reliability, predictability and user-friendliness for part manufacturers, said David Romlin at Seco Tools.

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.

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

In numerical-control applications, a cut shorter than the programmed cut resulting after a command change in direction. Also a condition in generated gear teeth when any part of the fillet curve lies inside of a line drawn tangent to the working profile at its point of juncture with the fillet. Undercut may be deliberately introduced to facilitate finishing operations, as in preshaving.

TungAluMill is intended for efficient machining of aluminum alloys and other non-ferrous materials at high speeds. The tool is designed to eliminate radial insert displacement caused by heavy cutting forces and strong centrifugal forces during high-speed rotation of the cutter, which is essential for efficient machining of aluminum parts. Additionally, the insert’s top and peripheral surfaces are ground and polished to a mirror-like finish, resulting in high-positive and sharp cutting edges that ensure soft cutting action, good surface finishing quality and prevention of built-up edge formation on the cutting edge.

Customers additionally are looking for new avenues to partner and integrate with tool suppliers, said Robert Bokram at Ceratizit USA.

Tools and techniques, however, are available to further reduce production costs and the cost per cutting edge when using indexable inserts. This article covers double-sided inserts and high-feed indexable insert milling tools.

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).

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.

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.

(Editor’s note: The lead angle is the angle between the side-cutting edge of the insert and the line parallel to the axis of rotation while the approach angle is the angle between the side-cutting edge of the insert and the line perpendicular to the axis of rotation.)

Attend TASC, The Automated Shop Conference, in Novi, Mich on Oct. 11, 2023 for a comprehensive look into how to use automation to transform your machine shop.

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

Effective team collaboration is a critical component of success in today’s manufacturing world. With cloud-based technologies that make it easy for team members to brainstorm and problem solve remotely from various locations, design-to-manufacturing processes can become faster and more efficient. This webinar will demonstrate how fully integrated CAM software can be utilized with 3DExperience SolidWorks in a seamless work environment to accelerate product development. Agenda: See how HCL CAMWorks can be used as an add-in for all SolidWorks applications working with the cloud-based 3DExperience platform Learn how fully integrated CAD/CAM saves significant amounts of time during the design to manufacturing process Gain a new understanding of how software can connect users worldwide to accelerate product development Watch a demonstration of team collaboration using platform tools in the CAD/CAM software environment

“Self-learning functions optimize real-time operations with adaptive control limits based on actual machining and tooling conditions,” he said, “so each machine can adaptively adjust machining parameters to operate at optimal conditions.”

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

Romlin said there is also a movement away from having a large inventory of tools with different variances. Instead, tool manufacturers must produce cutting tool designs and grades that are suitable for a broader window of applications than in the past.

“You gain a lot of stability compared to a 90-degree shoulder mill where the forces are predominantly radial, causing greater stress on the spindle and risking vibration issues,” he said.

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

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

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

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.

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

“An operator doesn’t necessarily have the knowledge to do so,” he said. “Sometimes they don’t have the authority to do so.”

Indexable insert tools enable manufacturers to machine parts with carbide and other hard materials without having to purchase a solid cutting tool made of the same material as the cutting edges — a progressively expensive proposition as tool diameter increases.

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.

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.

“It was a big improvement in process reliability, productivity and stability because the force being applied is less as you start to use the high-feed concept,” Romlin said. “This is one of our fastest-growing product areas, supporting the need for productivity improvements in the manufacturing industry. The high-feed concept is now an established machining method.”

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

Are AMRs the next big trend in job shop automation? System 3R’s IMTS booth will emphasize both its specialty EDM tooling and its automation products, including an autonomous moving robot.

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

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

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.

Robert Bokram, product manager for cutting tools at Ceratizit USA Inc. in Warren, Michigan, said toolmakers can offer double-sided milling inserts that have negative clearance geometries and high-positive rake angles.

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.

Are AMRs the next big trend in job shop automation? System 3R’s IMTS booth will emphasize both its specialty EDM tooling and its automation products, including an autonomous moving robot.

Double-sided inserts have a long history in metalcutting of reducing the cost per cutting edge, but cutting tool manufacturers continue to refine them and introduce offerings. Vernon Hills, Illinois-based YG-1 Tool (USA) Co., for example, announced that its new ENMX09 double-sided inserts have a total of four cutting edges and are suitable for high-feed milling.

Bokram said a common application for high-feed mills is helical interpolation, in which the high metal removal rate provides a fast, economical way to produce a large-diameter hole or counterbore, though more slowly than an appropriately sized drill.

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."

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

Angle of inclination between the face of the cutting tool and the workpiece. If the face of the tool lies in a plane through the axis of the workpiece, the tool is said to have a neutral, or zero, rake. If the inclination of the tool face makes the cutting edge more acute than when the rake angle is zero, the rake is positive. If the inclination of the tool face makes the cutting edge less acute or more blunt than when the rake angle is zero, the rake is negative.

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 exception is when the depth of cut exceeds the standard value and engages the adjacent edge, including the wiper on that edge,” he said. “Then, lower surface quality can be expected. This can be addressed with the addition of a wiper insert into one of the pockets.”

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.

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.

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

High-feed indexable insert milling tools are also widely available to up throughput. Andersson said this started several decades ago with round inserts, which have a continuously variable lead angle, depending on the DOC in relation to the radius.

Women in Manufacturing is excited to announce that the 2024 SUMMIT will be a hybrid event — both an in-person and virtual experience. Both program offerings will enable you to grow through education and connections that are insightful, meaningful and actionable. Join Women in Manufacturing Oct. 6-9, 2024, in Boston or digitally for an event filled with plant tours at leading manufacturing facilities, professional development sessions, roundtable discussions on important topics, and inspiring keynotes.  All while engaging and interacting with peers through social and networking events! __PRESENT __PRESENT

In addition, Carlile said the dovetail design enables the toolmaker to manipulate how the insert sits in the pocket.

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

Space provided behind a tool’s land or relief to prevent rubbing and subsequent premature deterioration of the tool. See land; relief.

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

Strip or block of precision-ground stock used to elevate a workpiece, while keeping it parallel to the worktable, to prevent cutter/table contact.

Nonetheless, Bokram said that shallow approach angle causes the net resultant machining forces to be exerted mainly along the axis of the milling cutter.

Machining operation in which metal or other material is removed by applying power to a rotating cutter. In vertical milling, the cutting tool is mounted vertically on the spindle. In horizontal milling, the cutting tool is mounted horizontally, either directly on the spindle or on an arbor. Horizontal milling is further broken down into conventional milling, where the cutter rotates opposite the direction of feed, or “up” into the workpiece; and climb milling, where the cutter rotates in the direction of feed, or “down” into the workpiece. Milling operations include plane or surface milling, endmilling, facemilling, angle milling, form milling and profiling.

“That said, the milling method requires significantly less horsepower than drilling from solid,” he said, “so the milling solution is often used when the customer is restricted by low-power machines.”

Carlile said one benefit is an increase in the cross-sectional thickness of the insert to permit more aggressive cutting than past products and provide adequate space for including Iscar’s signature dovetail clamping configuration on the top of the insert. The dovetail traps the insert rigidly in the pocket and takes pressure off the screw, he said.

“You have to look at the entire process to drive down production costs,” Andersson said. “You can’t pick tooling in a vacuum. When you are talking about new technologies, it all comes down to how you build new technology into your new release or product to aid not only in having the right speed and maximum chip control, but the absolute key part is predictability.”

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

“They are seeking ways to integrate Industry 4.0 technologies to expand the automatization of machining functions and eliminate manual intervention,” he said. “This requires the digitalization of multiple machining functions and the capacity to provide reliable technical support remotely, especially in today’s environment where plant access might be hindered by company policies surrounding employee safety.”

Distance between the bottom of the cut and the uncut surface of the workpiece, measured in a direction at right angles to the machined surface of the workpiece.

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

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.

Structured light scanning is used to create a digital twin of a manufactured part, but we must understand the measurement reproducibility to best use the data.

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.

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

Alan holds a bachelor’s degree in journalism from Southern Illinois University Carbondale. Including his 20 years at CTE, Alan has more than 30 years of trade journalism experience.

A grooving attachment enabled Keselowski Advanced Manufacturing to reduce cycle times by over 45 minutes on a high-value, high-nickel part feature.

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.

“The support function of the tooling manufacturer changed over the years,” he said. “It’s much more technical now.”

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.

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

Increasing the feed rate achieves this objective. Having wiper geometry on each cutting edge to improve surface finish enables end users to have the option of increasing the feed while maintaining the same surface finish as a conventional geometry, Bokram said. All Ceratizit USA positive/negative double-sided inserts have its Masterfinish wiper geometry on each edge.

Runs endmills and arbor-mounted milling cutters. Features include a head with a spindle that drives the cutters; a column, knee and table that provide motion in the three Cartesian axes; and a base that supports the components and houses the cutting-fluid pump and reservoir. The work is mounted on the table and fed into the rotating cutter or endmill to accomplish the milling steps; vertical milling machines also feed endmills into the work by means of a spindle-mounted quill. Models range from small manual machines to big bed-type and duplex mills. All take one of three basic forms: vertical, horizontal or convertible horizontal/vertical. Vertical machines may be knee-type (the table is mounted on a knee that can be elevated) or bed-type (the table is securely supported and only moves horizontally). In general, horizontal machines are bigger and more powerful, while vertical machines are lighter but more versatile and easier to set up and operate.

However, limitations exist for inserts with edges on both sides. For example, Romlin said there’s a trade-off in productivity for double-sided inserts because the number of teeth in the cutter is slightly lower than for single-sided inserts.

“They don’t want to have any technical question marks in terms of indexing and handling the tools,” he said. “They want to do that with limited instructions. That is a challenge to provide safe solutions where you cannot make mistakes.”

Developments in production technology have enabled tool manufacturers to increase the capability of double-sided inserts. Arlington, Texas-based Iscar USA, for instance, employs pressing technology with multiple stamping heads to increase the complexity of its double-sided inserts, said Keith Carlile, national product specialist for milling, who’s based in Centralia, Washington.

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.

However, drawbacks exist. Bokram said a high-feed mill can impart poor surface finishes, so it’s applied only for roughing, and the DOCs are restricted because of the shallow approach angle.

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.

“This means that high-feed designs are useful for long-reach applications because they generate very little vibration,” he said. “They also minimize radial force stresses on the spindle.”

“Unlike pos/pos single-sided insert designs, they cannot perform ramping, plunging or contouring,” he said. “But they are well suited for face and shoulder milling, depending on the approach angle of the cutter.”

Lee Wimmer invited us to tour his second-generation family-owned machine shop in Perkasie, PA. This video explores the production processes behind precision-machined parts for both Wimmer Custom Cycle and LS Wimmer Machine Co., and shows how ingenuity and determination are still at the heart of American manufacturing. Today, both companies are now managed by Wimmer’s three sons.

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

One shift for tool manufacturers is a result of a change not in customer relationships but the climate. As the automotive industry transitions from internal combustion engines to electric motors, Keith Carlile at Iscar said toolmakers will find more competition for cobalt, a key ingredient in both carbide cutting tools and lithium-ion batteries. He predicts that cutting tools will need to be designed to help conserve carbide while more emphasis will be placed on recycling the hard metal.

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

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.

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

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

Tough, difficult-to-machine alloys; includes Hastelloy, Inconel and Monel. Many are nickel-base metals.

“They can handle heavier depths of cut and higher feed rates than conventional positive designs due to better support in the pocket,” he said.

Loosely, any milling tool. Horizontal cutters take the form of plain milling cutters, plain spiral-tooth cutters, helical cutters, side-milling cutters, staggered-tooth side-milling cutters, facemilling cutters, angular cutters, double-angle cutters, convex and concave form-milling cutters, straddle-sprocket cutters, spur-gear cutters, corner-rounding cutters and slitting saws. Vertical cutters use shank-mounted cutting tools, including endmills, T-slot cutters, Woodruff keyseat cutters and dovetail cutters; these may also be used on horizontal mills. See milling.

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

Angle between the side-cutting edge and the projected side of the tool shank or holder, which leads the cutting tool into the workpiece.

“The double-sided insert requires a thicker core,” he said, “and hence (you) need more seat space in the cutter design.”

“The ‘pos/neg’ pocket orientation allows for insert designs that double the number of cutting edges per insert, utilizing higher rake angle chipbreaker geometries to compensate for the negative pocket orientation,” he said. “These more robust designs have proven to be very soft cutting, demonstrating similar spindle torque values to the conventional ‘pos/pos’ milling cutter designs.”

“In the end,” he said, “the user must calculate the comparative metal removal rates to alternative milling system designs, based on the milling operations they are performing.”

David Romlin, corporate product manager for indexable milling tools at Seco Tools AB in Fagersta, Sweden, said a time-tested double-sided insert is the Double Octomill, which has eight cutting edges per side for facemilling operations. (Seco Tools LLC is in Troy, Michigan.) A more recent development is the Double Turbo square shoulder mills that accept inserts with four cutting edges, which have an 11-degree positive helix angle to reduce power consumption.

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

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!

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.

Groove or other tool geometry that breaks chips into small fragments as they come off the workpiece. Designed to prevent chips from becoming so long that they are difficult to control, catch in turning parts and cause safety problems.

Studies by YG-1 Tool (USA) showed that end users either used only one side of a double-sided, high-feed insert or accepted that they would obtain only 60% to 80% of the tool life for the second side compared with the first side when they used both sides, Andersson said.

In addition to square inserts with eight cutting edges and octagon inserts with 16 edges, Carlile said Iscar offers the H606 double-sided round insert with six total edges. The insert gives adequate room for a helix angle on the outer diameter to supply a shearing rather than a pounding cutting action. He said an undercut feature on the bottom of the insert bisects a chip and reduces the amount of force it takes to remove the chip.

Any machining process used to part metal or other material or give a workpiece a new configuration. Conventionally applies to machining operations in which a cutting tool mechanically removes material in the form of chips; applies to any process in which metal or material is removed to create new shapes. See metalforming.

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.

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

Bokram said high-feed milling tools use a simple design feature to fundamentally change machining parameters, often resulting in significantly higher total metal removal rates than conventional 45- and 90-degree designs. By reducing the approach angle of the cutter to 15 to 20 degrees, the resultant average chip thickness is reduced, which commonly is known as chip thinning.

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

Reduction in clearance on the tool’s flank caused by contact with the workpiece. Ultimately causes tool failure.

“If the machine can’t do linear travel fast enough,” Carlile said, “just increase your lead angle and take a deeper depth of cut.”

In addition, machine operators don’t have a journeyman machinist’s in-depth knowledge and are tasked mainly with activities, such as changing parts, pushing the start button and indexing inserts, Andersson said. In contrast, a machinist can make on-the-fly changes and tweak a process to improve it.

Automating functions like process and tool wear monitoring, tool failure and collision detection, and adaptive feed control can reduce tool costs, tool breakages, scrap and overloads, Bokram said, noting that Ceratizit offers ToolScope for doing those tasks and more.

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.

“Making a thicker insert allowed us to accept that flank wear but without having the encroachment issue,” he said. “This means four true cutting edges.”

“What makes them unique is the thickness, which addresses one of the major issues you have with double-sided, high-feed inserts,” said Jan Andersson, director of product management for indexable inserts. “The nature of the application is that you will always have flank wear on the bottom of the insert.”

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?

Angle between the insert’s side-cutting edge and the line perpendicular to the milling cutter’s axis of rotation. Approach angle, which is also known as cutting edge angle, is used with metric units of measurement. See lead angle.

“In order to increase the chip thickness to the ‘normal’ range for the insert edge geometry, the feed rate (ipm) must be increased,” he said. “The result is higher cutting speeds and ultimately higher metal removal rates.”