Grooving Insert MICRO-Line B 1,50 CBN-H - micro grooving full radius insert

 2024-06-24 12:25:59

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

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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.

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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.

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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.

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."

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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.

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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.”

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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).

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

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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.

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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.

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.

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.

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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).

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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.

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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.

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.

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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

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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?

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

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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.

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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.”

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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.

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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.

Grooving Insert MICRO-Line B 1,50 CBN-H - micro grooving full radius insert

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