Compared to carbide, the binderless CBN ran three times faster, removed nine times the material and lasted 3 times longer on a single cutting edge.

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

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 extent of these broader benefits depends on the extent to which performance benefits and economies of scale drive the expansion of binderless CBN (and perhaps other varieties of binderless insert) into new applications and materials. Meanwhile, the new NCB100 binderless CBN offering provides a ready alternative for work that otherwise would require redundant tooling and/or accounting for insert changes, wear-offset entry and the risk of tool breakage during lengthy, automated machining cycles.

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

The binder in most CBN inserts can act like a shock absorber, but only at the expense of some of CBN’s natural advantages. Photo Credit: Sumitomo Electric Carbide, Inc.

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.

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

The two flat, parallel horizontal lines represent surface finish (gray) and insert wear (blue) with the carbide insert after 45 minutes of machining at 200 sfm. The vertical blue bars indicate the progression of binderless CBN insert wear over time at both 400 SFM (light blue) and 600 SFM (dark blue). The second pair of horizontal gray bars show surface finish deterioration over time with binderless CBN at 400 SFM (light gray) and 600 SFM (dark gray). Photo Credit: OMIC

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.

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

Testing continued. Pushed to 600 sfm – three times the speed of carbide – the binderless CBN lasted more than 400 minutes before exhibiting the same level of flank wear as the carbide insert at 45 minutes (although with CBN, surface roughness had reached nearly 65 Ra by the 400-minute mark). At the 435-minute mark, chips began to become progressively long and stringy. Finally, at 555 minutes, the insert tip wore into a crescent shape, “much like sanding a block of wood down on a belt sander,” says Cody Apple, machining solutions researcher at OMIC. “This was predictable and easy to detect when it occurred.”

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

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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."

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.

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.

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.

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

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.

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.

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

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."

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.

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

Yet, binder can do more than just hold insert material together. Jason Miller, a national applications engineer with Sumitomo at the time of this writing, says it also acts much like an automobile suspension, which employs springs and other shock absorbers to smooth the ride. In fact, specially formulated binders help other CBN inserts withstand the forces associated with gear machining and other interrupted-cutting applications that are hard on tooling. Applying the new binderless inserts for such work would be “akin to applying a drag car to drive over a mountain,” he says. “It doesn’t work.”

Mastercam 2025 incorporates big advancements and small — all based on customer feedback and the company’s commitment to keeping its signature product best in class.

Two of the CBN inserts, one with a low rake angle and one with a high rake angle, experienced similar levels of tip wear after 45 minutes (0.0024 inch for both CBN geometries). At this point, the carbide insert required indexing to maintain chip control. However, both CBN inserts continued to produce short, tightly curled chips. A third binderless CBN insert, this one with a medium rake angle, performed even better, wearing only half as much (0.0012 inch) at the 45-minute mark.

This is not to suggest that titanium turning is the only potential application of binderless CBN, nor that milling or other interrupted cutting is out of the question. On the contrary, Sumitomo reports that the inserts have been applied successfully in interrupted cuts in both powder metal and cast iron, as well as hardened steel milling in certain conditions. Meanwhile, development continues on different edge geometries and CBN particle-size formulations that add strength and toughness. The tools have also been been applied to turn medical parts from such materials as cemented carbide and cobalt chrome (Co Cr).

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.

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.

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

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

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

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Tool-holder-spindle-machine combinations each have a unique dynamic response in the same way that each person has a unique fingerprint, which can be revealed using modal testing.

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.

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.

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

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

Urmaze Naterwalla, OMIC head of R&D, analogizes traditional, “bindered” inserts to a road, with the individual particles embedded in the surface representing the cutting material (CBN in this case) and the tar representing the binding material. The binding material is softer, so it breaks down first as the surface deteriorates. It tears away in chunks to leave potholes. Without the tar, the particles are fused directly to one another. There are no potholes because the surface wears away at a relatively constant and predictable rate, resulting in two parallel divets carved from the wheels of passing traffic.

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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.

The primary difference between this CBN and other inserts is not what it contains, but what it lacks: a binder to hold the sintered material together. Rather, the nanoparticles are fused directly to one another to form a virtually solid, continuous cutting surface. This construction enables taking full advantage of CBN’s extreme hardness and thermal conductivity in a material that is notorious for work hardening.

The higher-temperature, higher-pressure sintering process that makes binderless construction possible is significant for more than just machining performance. Cobalt, a critical ingredient in the “cement” that holds cemented tungsten carbide together, is increasingly rare and costly. The case is the same for tungsten, Niobium and other elements of these inserts. Eliminating the need for these materials in a cutting tool eliminates the need to pull them from the Earth, thus preserving precious resources while benefitting the environment as well as people directly affected by the mining.

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

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.

Nonetheless, a drag car is ideal for rocketing down a perfectly smooth road. And for binderless CBN, the continuous surfaces of titanium aerospace parts like the ones machined at OMIC are essentially racetracks. Interruptions are rare, and cutting depths are shallow, recommended at only 0.020 inch in titanium.

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 devising its hard-turning strategy, this die/mold shop has been able to speed the production of its new deep-draw round tooling offerings by turning them instead of grinding them after heat treating.

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).

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.

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

Moving from cut tapping to form tapping for a notable application cut tooling costs at Siemens Energy and increased tool life a hundredfold.

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.

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

At 400 sfm (twice the speed of carbide) and 230 minutes in the cut, the binderless CBN insert was still performing consistently. The carbide insert required indexing at the 45-minute mark. Photo Credit: OMIC.

We understand that if an item isn’t correct, then it needs to be returned. If you are wanting to return anything supplied by Trucut Tools please see our Shipping & returns page for full instructions..

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.

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.

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.

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.

*T’s & C’s and exclusions apply. Please see our Shipping and returns page for more information on all our services including those outside of mainland UK (Republic of Ireland, Northern Ireland, Scottish Highlands, Channel Islands etc).

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.

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.

Meanwhile, the advance of additive manufacturing could intensify focus on finishing and semi-finishing over roughing. Compared to carving out solid billets or blocks of material, machining 3D-printed, near-net-shapes requires different techniques and different cutting tools. “This means shifting to cutters that require less radial engagement but will move with more speed,” Mr. Apple says.

The company has enhanced its 52/96 zero-point workholding system with a new vise, collets machinable hard jaws and more.

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

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

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

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

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

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

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?

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.

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

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

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.

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!

A new formulation of cubic boron nitride could provide a more solid alternative to cemented carbide as finish-machining becomes more demanding.

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.

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.

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

A high-pressure, high-temperature sintering process enables fusing submicron-size grains of CBN together without binder to maximize hardness, thermal conductivity and the resulting advantages in titanium and cobalt chrome. Photo Credit: Sumitomo Electric Carbide, Inc.

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.

The biggest difference was speed. In repeated testing, all three CBN geometries ran at 400 sfm, versus only 200 sfm for the cemented carbide. Nonetheless, OMIC was not finished. Researchers pushed the highest-performing CBN insert (with the medium rake angle) well past the 45-minute mark, and they extended periodic wear measurements from 15- to 30-minute intervals. After 230 minutes, chips were virtually indistinguishable from those generated at the 45-minute mark. In contrast, the carbide insert had worn twice as much, was removing only half the material, and was leaving a rougher surface.

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

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.

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

The finish-turning tests were conducted at the Oregon Manufacturing Innovation Center (OMIC), a nonprofit collaborative research organization near Portland, at the request of the inserts’ developer, Sumitomo Electric Carbide, Inc. OMIC ran three NCB100 binderless CBN turning inserts against the AC51015S cemented carbide grade that Sumitomo would otherwise have recommended for the application. As expected, the carbide performed well in repeated tests, exhibiting 0.00208 inch of tip wear after 45 minutes in the cut. “There were no anomalies to note during these trials,” reads an OMIC report on the tests. “The insert showed even and predictable wear over time, creating a great baseline to compare from.”

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.

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

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.

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

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.

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 Cut F 600 wire EDM features machining enhancements and functions to automatically identify and adapt wire speed during the wire EDM process.

Although carbide inserts are proven performers in virtually all types of CNC machining, aerospace alloy finishing presents a particularly good opportunity to start exploring alternatives. In recent testing, a new type of cubic boron nitride (CBN) finish-turning insert ran three times faster, lasted three times longer and removed nine times the material as cemented carbide in titanium 6AL-4V, all on the same cutting edge. “Consistent chip control and a long-lasting edge make this a great candidate to replace current stable finishing processes using carbide,” the researchers wrote.

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.

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

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.

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

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

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.

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.

Research also continues into other binderless formulations. In fact, Sumitomo first applied its new direct conversion sintering process for binderless polycrystalline diamond (PCD), which is useful for machining tungsten carbide drawing dies and wear plates as well as ceramic materials. The company expects applications for these tools, and potentially others, to expand along with demand for new, highly durable yet difficult-to-machine materials for spacecraft, aircraft, automobiles, medical and electronic components and more. “We should recognize that there’s going to be an evolution, just like there was with carbide,” Mr. Naterwalla says. “The more we adapt to what this is capable of, the more that evolution will move forward.”

The design freedom of additive manufacturing delivers increased performance to cutting tools. At the world’s leading exposition for machine tools, I saw various examples of this.