Groove Hard - tungsten carbide grooving insert

 2024-09-08 12:46:01

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).

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.

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

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.

Currently, the NEO-DO S890 only has one edge geometry, which is suitable for ISO P and ISO K materials. “We will be adding a high-positive (HP) geometry,” Stusak says. “This will be suitable for difficult-to-machine materials such as stainless steel.” However, ISO P and ISO K materials make up a hefty portion of automotive manufacturing, the primary market this tool is designed to serve. The inserts come in a T-Land edge preparation for cast iron and an MM edge prep for steels.

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.

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

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

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

Some milling jobs feed at 200 IPM @ 2,500 SFM without catastrophic edge failure. Turning feeds up to 0.01 IPR @ 1,200 SFM are routine. “With the other ceramics we tried, whiskered or unwhiskered, the milling was not up to our standards,” said Hub Whitley.

Edge preps for the NEO-FEED come in HP for stainless steels and exotic alloys, as well as in T-Land for general-purpose machining. As with the NEO-DO, the NEO-FEED benefits from the rigidity of the dovetail pocket design and the cost-per-edge of double-sided square inserts.

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.

There are pluses and minuses to working in the machine shop at MOGAS Severe Service Ball Valves. On the plus side, there’s plenty of work despite the ongoing economic uncertainties; as part of a global corporation, the Houston-based process valve manufacturer is busier than ever. The backlog of orders is so extensive that the CNC department and manual machine shop must run 24/7 just to keep up.

Ceramic, but built for roughing A key factor in the performance of the Ingersoll AS20 ceramic is the toughness of the SiN substrate, combined with a very strong geometry and special edge prep. Unlike most ceramics, the AS20 is designed specifically for roughing, and in particular features a wide land. Top-face geometry puts more of the machining heat into the departing chip than into the tool, toolholder, or workpiece. This not only protects the insert, but also helps speed up indexing.

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

One easy-to-control factor that can improve the reliability and accuracy of milling these features is the cutting tool. Cutting tools with 90-degree lead angles generate radial cutting forces that transfer more of the cutting energy away from the part. This makes them ideal for parts with thinner walls or near-net shapes, as well as for parts with less rigid fixturing. Knowing that near-net and 3D-printed parts are growing more common, Iscar recently developed a square insert designed for finishing complex parts.

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

The principal parts in MOGAS ball valves are the balls and their mating valve seats. Such valves help control hot, corrosive process fluids found in refining, chemical and mining operations. Each valve has one ball and two valve seats that require precision machining for the valve to be truly leak-proof. The ball has a bore down its center, rotating the ball opens and closes the flow of material.

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

Kippola’s recommendation for both turning and milling: Ingersoll ceramic grade AS20 SiN inserts, running at roughly twice the speed of any other ceramic tried. To Horton’s surprise, the inserts were “unwhiskered” (no microscopic reinforcing fibers), with special edge preparation. Turning inserts are plain rounds, which rough at 1,200 SFM. Milling inserts, seated in a 2-inch shell mill, are notched for better gripping in the seat pocket to withstand the extremely fast rpm’s. Standard speed: 2,500 SFM.

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.

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.

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.

Based on success with the Inconel balls and seats, Horton is running the same Ingersoll ceramic insert to turn valve stems, and is doing a considerable volume of boring, too. “We’re pushing the envelope regarding boring Inconel with ceramics, with excellent results” says Horton. “We’ve heard that many shops avoid boring Inconel with ceramic inserts because the material doesn’t tolerate the recutting very well. With this particular Ingersoll grade and special attention to chip evacuation, our boring operations have been very successful.”

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

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

While the NEO-DO S890 is currently able to cut ISO P and ISO K materials, the company plans to expand its range to more difficult metals.

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.

Indeed, heat management in a broader sense helped to shorten cycle times in other ways. Keeping the tools just warm to the touch will shorten indexing downtime to a measurable degree. “We’re deliberately accepting high edge wear in exchange for higher throughput, which necessarily means more frequent indexing,” says Horton. “Naturally we want to avoid indexing delays due to inserts becoming too hot to handle right away.” Kippola added that he has seen processing at other plants delayed for 10 minutes or more, waiting for the tool to cool off enough to handle.

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!

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

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.

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.

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Iscar has also recently developed double-sided square inserts for its high-feed NEO-FEED line. “The industry is trending toward high-feed milling to take advantage of improved material removal rates,” Stusak says. “We developed the NEO-FEED to accommodate this need.” The NEO-FEED insert can work with one of two cutter body designs.

Of course, a major benefit from developing the NEO-DO S890 as a square insert is the cost savings. “Of all our 90-degree inserts, this has the lowest cost per edge,” says Stusak. “This is especially important for high-production environments.” The company’s many other 90-degree insert offerings are rectangular, triangular, and trigon in shape, meaning there are only four-to-six edges per insert compared to the NEO-DO’s eight.

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

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

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."

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

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Once the requisite stability was established, the MOGAS CNC team modified the programs for more aggressive toolpaths, and then turned to Kippola and Higby to optimize the final machining parameters. The critical detail of their strategy was to push machining rates, even at the expense of edge life. “Sure, ceramic inserts aren’t cheap, but the real potential for money saving is to speed up the chipmaking and let the rest fall where it may,” said Horton.

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

Faster machining, reliably In initial trials, the Ingersoll solution achieved slightly higher rates than other ceramics, but did so with much more reliability. Failure causes were edge wear (which was very predictable), not edge rupture (which is not.) “Performance was especially impressive on milling, with its interrupted cuts that often fracture brittle ceramics,” said Hub Whitley.

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.

Additionally, the insert can maintain a high degree of rigidity thanks to the design of its dovetail profile in the insert pocket. The dovetail connection relieves tension from the clamping screw while simultaneously reducing movement. The insert is connected axially and radially, and the flanks of the insert are tapered to provide further support. All these features combine to provide a highly rigid insert, which can decrease runout, improve the finish, reduce wear on the inserts and increase the feed rate. “A good cutting tool is not just about the cutting-edge geometry,” Stusak says. “Many different features come together to create an insert that has the cutting-edge profile, clearance, rigidity, and material removal rate needed for the task at hand.” Even the 8-millimeter IC size of the insert plays a role, as it provides room for more inserts around the tool’s circumference, thus boosting productivity.

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

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

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.

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

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.

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

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

As a double-sided square insert, the NEO-DO S890 has more cutting edges than any other 90-degree milling insert Iscar provides. This makes it an economical choice for finishing near-net shaped parts..

Each tool setting technique has merit, and it depends on where you are as a shop and the type of work you do, as cost and efficiency all come into play.

The 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.

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.

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

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.

The outcome: a secure process for roughing Inconel, which runs twice as fast as with any other ceramic. For example, turning a ball that used to take an entire shift with carbide, and two hours with other ceramics, now takes an hour. A seat ring that once took an hour with carbide, and 30 minutes with other ceramics, is now completed within 15 minutes.

On the other hand, to fill all those orders MOGAS must machine a lot of “uncooperative” Inconel 718. That heat-resistant alloy is notorious for burning up tools and generating long, stringy chips with a proclivity for adhering to cutting edges. This limits cutting rates and necessitates frequent but unpredictable stoppages for indexing — considerably upsetting that round-the-clock schedule.

For shops that do not have the advanced machine tools necessary to maintain extremely high feed rates, the company also make a moderate-feed cutter offering. This cutter uses the same NEO-FEED inserts, but with a 22-degree lead angle resulting in a 0.118-inch depth of cut. “The increased depth of cut partially compensates for the lower feed rate when it comes to material removal,” Stusak says. “This is really a hybrid option of a high-feed tool and a face mill. It won’t reach the feed rate of the high-feed tools, but it is certainly faster and more aggressive than a traditional 45-degree face mill.”

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

It is also worth emphasizing that this is not a nearly 90-degree cutter, but a true 90-degree cutter. “There are other square inserts that provide an 88- or 87-degree lead angle,” says Stusak. “This means that after roughing the part, the user has to go back over it to achieve the 90-degree angle required by the specs.” The NEO-DO S890 enables the operator to perform a roughing and finishing pass on the part without having to change tools or go back over the same passes again. This saves both time and cost.

The first cutter body design is a “fast-feed” cutter that enables the user to tilt the insert at a 12-degree lead angle to the surface. “This enables the cutter to have what they term as an axial chip-thinning effect,” Stusak says. “This gives you a 0.060-inch depth-of-cut capability.” This provides ideal conditions for high-feed milling processes.

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.

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

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

Choosing the right milling insert is important: This insert from Iscar is designed for finishing near-net shaped parts quickly, while another makes high-feed machining more accessible with existing machining centers.

The automotive industry has embraced light-weighting, increasingly looking for manufacturers capable of producing near-net shaped parts, either from precision forged metals or in finishing processes for additive manufacturing (AM). Complex part designs are quickly becoming standard, but as much as complex shapes can benefit the final product, these shapes are thinner than those of most prismatic parts, which means there is less wiggle room in the cutting forces a machine applies to the part.

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

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.

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

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.

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

Commitment to ceramics Together with lead man Hub Whitley, Zach settled on ceramic tooling to replace the carbide components. They tried a few grades on their own and achieved 50% to 100% productivity improvements, but edge failures were so unpredictable that they defeated process stability. So, they called Ingersoll’s Craig Kippola and Kirk Higby of tooling distributor Cutting Tools Inc. for specific recommendations on grades and machining parameters. “They solved past problems for us very well, so they were the natural ‘go-to guys’ this time around,” said Horton.

In this episode of Made in the USA, several executives and senior staff at Hardinge give their first-person account of how they formulated the plan to shift the manufacturing of its milling and turning product lines from its Taiwan plant to its plant in Elmira, New York, the major challenges they encountered and the rewards that made it worth the effort.

Heidenhain and Acu-Rite Solutions are offering several hands-on experiences at their booth this year, as well as internal components that reduce energy use.

Manufacturing is a competitive industry in which machine shops across the world struggle to make parts more efficiently than their neighbors. This leads to new technologies improving machine performance often creating more complex parts for shops to cut. In this environment, something as simple as knowing the right cutter for the right job can give a shop the edge.

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

MOGAS makes the balls from chucked barstock: Bore out the main bore, mount it on a mandrel, turn the OD, then move the piece to another machine to pocket-mill a rectangular slot. The slots engage the valve stem as part of the rotation mechanism. The valve seats involve OD and ID turning only, with the ID a spherical radius to mate with the ball.

Last August, MOGAS CNC programmer/supervisor Zach Horton and his CNC team, together with Ingersoll’s Craig Kippola, attacked the problem head-on by seeking to find a faster, more reliable way to machine that most contentious material. As a result, they’re turning Inconel 718 valve balls four times faster than with carbide — and twice as fast as with any other ceramic they’ve ever tried. Similarly, the team improved rough milling rates by 5 to 1 over carbide, and again, 2 to 1 versus any other ceramic.

The NEO-DO S890 is designed to enable the operator to perform both roughing and finishing passes without having to change tools. The small inserts are ideal for making precise passes on parts with near-net shapes.

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

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

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Accordingly, MOGAS flood cools everything during turning ---work piece, mandrel, tool and tool holder. They run the milling dry, but flood the cutter and inserts for 15 seconds at every indexing stoppage. Horton won’t disclose the actual indexing frequency, but says it’s short enough to shock some people. “Nevertheless, we’re way ahead economically by burning through inserts in order to run faster. That’s a trade-off I’d take any day.”

The NEO-FEED inserts are designed to work with both a high-feed and medium-feed cutter. The medium-feed cutter in particular is designed to bridge the gap between traditional face milling and high-feed milling.

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

“Many people think that whiskered ceramics are intrinsically tougher than unwhiskered ones, but that’s ‘old school’,” said Kippola. “Newer, unsupported ceramics exhibit vastly improved toughness because of the substrates themselves.”

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

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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

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.

Four-part solution There were four parts to their solution: 1) retool with an Ingersoll ceramic insert, with special edge preparation; 2) inject some “out of the box” programming; 3) sacrifice edge life for exponential gains in feeds and speeds as a matter of strategy; 4) and control process heat to speed up edge indexing.

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.

The NEO-DO S890 is a 90-degree, double-sided, square milling insert from Iscar designed for combination applications, i.e., face and shoulder milling, and finishing near-net shaped components. “One of the challenges of designing a true 90-degree square insert is having enough axial clearance on the bottom of the insert so you’re not rubbing too much,” says Iscar National Product Manager - Milling, Bryan Stusak. “The geometry of this insert enables a true 90-degree angle while increasing the number of edges per insert over our previous offerings.” The true 90-degree angle, combined with a 0.200-inch maximum depth of cut makes this ideal for making finishing passes, especially on complex parts. “Printed and near-net shaped parts have very little material to remove,” says Stusak. “This insert is ideal for that environment, as it enables the cutter to make precise passes while minimizing the potential for damaging the part especially where there are workpiece or work holding fixture constraints.”

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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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.

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?

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

Groove Hard - tungsten carbide grooving insert

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