End Mills – Carbide – 4 Flute – Extra Long - Sutton Tools - four flute end mill

 2024-09-15 09:58:46

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

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.

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 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.

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

4150 steel machining in action. The workpiece here is hardened to 54 HRC. The solid-body ceramic milling tool is 0.75 inch diameter. Cutting speed is 1,500 sfm. Feed rate is 0.001 ipt for a full-diameter slotting pass at 0.125 inch axial depth of cut, and 0.0024 ipt for a profiling passes at 0.125 inch axial depth of cut and 0.060 inch radial depth of cut.

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

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.

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

DART's brad point wood drill bits feature two flutes to prevent materials from clogging the hole, which allows for precision cutting and smoother finishes. Explore our range in full below for further information, and find your local stockist using our stockist map locator!

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

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).

Material advances have produced a ceramic end mill that performs well at lower cutting speeds and competes with carbide in a broad range of applications. Your shop might begin using ceramic tools.

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

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

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.

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

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.

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

Four-flute ceramic end mills are available in cutting diameters from 3/8 to 3/4 inch. Stability is a requirement for using the tools well. The flute design for minimizing vibration is thus an important part of the engineering.

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.

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."

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.

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.

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

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.

Like other ceramics, this tool cuts dry and likes high cutting speeds. The crucial difference: The new phase-toughened solid-body tool performs well at cutting speeds that are low for ceramics, coupled with feed rate that is relatively high. The result is a solid ceramic round tool well suited to the capabilities of standard machining centers. All photos courtesy of Greenleaf.

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

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

We stock an exceptional range of precision-engineered brad point drill bits suitable for hardwood, softwood and man-made boards. Each brad point drill bit is manufactured from high grade steel for ultimate accuracy and precision. These feature a highly sharp point for precise tear-free holes.

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 cutting tools offer a model case for appreciating the distinction between hardness and toughness. These very hard tools have long been a solution for machining very hard metals such as aerospace alloys. However, turning has been their principal application, because of a relative lack of toughness. The tools stand up to consistent high forces such as the steady cut in uninterrupted turning — thank you, hardness — but they are vulnerable to the bang-bang-bang shocks of an interrupted process such as milling, because enduring shocks is what toughness is all about.

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

In test cutting, the performance and promise of the new round tools have been seen not principally in the high speeds these tools are able to achieve, but instead — stay with me on this — important improvement has been found at the low speeds at which these tools cut well. Ceramic tools are generally run at very high speeds (and run dry) because the ceramics’ thermal coefficient makes the tools so heat-resistant. The tools even have minimum cutting speed thresholds for optimal performance. However, the new, tougher ceramic tools do not need the intensity typical of ceramics. The optimal speed range for the new solid ceramic end mills begin at 1,300 sfm, low compared to other ceramic cutters. For a 1/2-inch end mill, that is about 10,000 rpm. In short, the needed speed is accessible to a broad range of machine tools used by a broad range of shops.

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.

Now, ceramic cutting tool maker Greenleaf says innovations in the toughness of ceramics within the last five years offer the potential to dramatically expand the applicability of ceramic tools in milling. The company recently launched its “Xsytin 360” line of solid-body four-flute ceramic end mills, after two years of development. According to James Greenleaf, the third-generation owner of the company, these tools are “the most extensively tested product we have ever introduced.” And that testing continues, because a ceramic tool with greater toughness is a tool that potentially has promise within machining sectors and applications not typically associated with ceramics, involving shops that have not turned to ceramic tooling before.

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.

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

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

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

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

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

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

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.

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

Legacy Precision Molds takes us on a tour of their moldbuilding facility. They've recently implemented two automated 5-axis cells for metal and graphite machining that run lights out during nights and weekends.

The company also applied ceramic inserts to milling, albeit on larger-diameter tools. But now, the latest major advance in ceramic toughness has led the company to introduce smaller-diameter solid tools as well as inserted ballnose tools. This latest toughness advance is not because of the addition of a different reinforcing mechanism, but rather because of a proprietary phase toughening process that leads to greater control over the formation of the ceramic material, including the formation of the whiskers. As the company explains, phase toughening of the material delivers a stronger material substrate as well as more predictive performance in applications where other cutting tool ceramics are prone to failure. The material made this way still favors hardness over toughness, but now within a combination that not only provides for the requirements of smaller-diameter tools, but also lands nearer to the needs of general machining and to the performance capabilities of more mainstream machining centers.

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

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

Hardness and toughness together mean slow progress of tool wear. The edges of the 1/2-inch diameter ceramic end mill here show the wear after 72 minutes of milling for 64 cubic inches of material removal in 4150 steel with hardness of 52-55 HRC.

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.

It was a solution realizing greater toughness that drove Greenleaf’s first big breakthrough with ceramic tools, decades ago. The company introduced ceramic tooling in 1973, manufactured thanks to hot pressing technology that was proprietary at the time. But in 1985, the company proved and went to market with its method for adding reinforcing crystals grown in long, thin strands — known as whisker reinforcement — within the microstructure of the hard turning tools made this way.

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

Adopting PCD tooling has extended FT Precision’s tool life from days to months — and the test drill is still going strong.

Diagnosing when a tool is failing is important because it sets an expectation and a benchmark for improvements. Finding out why gives us a clue for how to fix it.

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.

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.

However, within the many shops able to achieve this level of stability and control, this tool is now a competitor to carbide in a way that ceramic round tools have not been before. The level of toughness resulting from the phase toughening has brought us to this point of change: In facing their challenges with hard metals, many shops will now consider ceramic milling tools that have never used tooling made of this material before.

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

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

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.

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.

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.

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

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

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?

That productivity improvement does need the right setup. The Xsytin 360 milling tools making use of the phase-toughened ceramic are not a replacement for carbide; we have been speaking of toughness, and carbide is still the tougher material. The ceramic end mills capable of lower speeds still need effective process controls against shocks to the tool — controls that include rigid fixturing; short overhang in the tool setup; a shrink-fit, press-fit or hydraulic toolholder for low runout; and a tool path ensuring continuous cutting by maintaining a consistent chip thickness. Indeed, the tool’s flute design is part of this formula and another important part of the engineering of the tool. This flute aids stability through a geometry that has been refined to minimize vibration. Also needed in the application of the tool: a way to clear chips from the path of the cut without coolant, because this ceramic, like earlier ceramic tools, does far better running dry.

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

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

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.

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

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

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 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.

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.

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!

Against carbide, the company reports productivity improvement on the order of a factor of 10 in milling hard steel, aerospace heat-resistant superalloys, compacted graphite iron and various hard alloys that are now finding use in production parts made through additive manufacturing processes such as laser powder bed fusion.

Yet even at a lower speed than is typical of a ceramic milling tool, the company says its testing in materials such as the aerospace alloy Inconel 718 still shows better metal removal rates and tool life than existing ceramic round tooling. This, too, is because of the freedom of toughness. The lower speed can be matched to a feed rate about 3.5 times that of what existing ceramic end mills accommodate. The result is an inch-per-tooth (chip load) feed rate equivalent to that at which the shop might be accustomed to programming carbide, yet at a much higher spindle speed than would be appropriate for a carbide tool.

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

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

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

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

The Xsytin 360’s SiAlON (a ceramic combining silicon, aluminum, oxygen and nitrogen) is a material about which James Greenleaf feels he can confidently say, “This is the strongest ceramic material on the market. We finally felt we had a ceramic good enough to offer a really effective round tool.”

Compared to carbide end mills, the ceramic tool can realize both a much higher cutting speed and a much higher feed rate for a higher metal removal rate overall. Shown here are parameters for machining Inconel 718. Note the ceramic tool’s speed, which, while high, translates to only about 12,000 rpm.

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.

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.

(Memory lane: My first job in industry was in a machining laboratory where we evaluated cutting tool performance in aerospace alloys. I spent a lot of time looking at WG300 inserts’ cutting edges under a microscope.)

Entrepreneur Scott Colosimo found early success in China producing parts for his Cleveland-based motorcycle company in the mid-2000s. This is the story of how IP theft issues overwhelmed the business, prompting Colosimo and his team to start over from scratch — and move production back to the United States.

The 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.

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.

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

That innovation multiplied the life of these ceramic tools by a factor of 10, and led to the company’s WG300 family of turning inserts.

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.

End Mills – Carbide – 4 Flute – Extra Long - Sutton Tools - four flute end mill

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