Hertel Metalworking Products - ball nose insert milling cutter

 2024-07-06 11:43:47

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.

“In hard milling you want to use an air/oil mist or air blast,” said Ball. “Coolant can thermal shock the cutting edge and prematurely wear out the tool. However, there are some cases where a manufacturer has to use coolant because it causes less wear than cutting hard chips. It’s a balancing act.

Ball said, “When you are high-speed machining you are taking a light radial and axial depth of cut, so you don’t have a tremendous amount of cutting pressure but you have to make sure your holds are rigid and balanced. You don’t see a lot of one-flute tools used in HSM because they are physically unbalanced by nature.

Forget “additive versus subtractive.” Machining and metal additive manufacturing are interconnected, and enhance the possibilities for one another. Here is a look at just some of the ways additive and machining interrelate right now.

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

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

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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.

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

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

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

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.

Depending on the manufacturer a tool may be designed with 1-1/2x, 2x, or 3x flute length diameter. The longer flute length is not as rigid as a short flute length so those tools may not work at the high speeds. Tools with shorter flute length need to be considered.

HSM generates a lot of chips very quickly. Ensuring their removal is critical whether you are dry machining and using an air blast, an air/oil mist, or using coolant.

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).

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

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

OSG’s A-BRAND® ADO-TRS drill is an advanced performance high-feed 3-flute carbide drill. Patented geometry provides stable chip ejection, even with less flute space inherent in 3-flute drills. The result is up to 3X faster cycle times and 3X longer tool life than 2-flute drills.

Successful high-speed milling requires a balance among every aspect of the cutting system, including the machine tool, software, chip removal, and cutting tool. Photo courtesy of Seco.

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

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

During the New Product Rollout in Rockford, Illinois, Jacob Harpaz — chairman and CEO of IMC Group, the parent company of Ingersoll — discussed the importance of continuously developing new technology. “We must innovate with the purpose of increasing customer profitability,” he says. To illustrate this, he discussed a wide range of new and current cutting tools that reduce machining time, focusing especially on high-feed machining.

Jay Ball, product manager--solid carbide end mills NAFTA, at Seco Tools LLC, said that it is important to have dedicated roughing and finishing tools. “Tight tolerances have become the industrial standard, and it is not uncommon for a customer to demand cutting tools with a 5-micron radius and diameter tolerance. Smaller tolerances are the wave of the future. To expect one tool to hold up during a roughing operation and use the same tool to finish and hold the tight tolerance is a stretch.”

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.

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

Some tools combine roughing and finishing, but different cutting edges for each step help the tool to perform to close tolerances.

Chip load is also an area for attention, said Ball. “Not maintaining a constant chip load is one of the biggest issues I see in HSM. Consider whether the part you are machining and the tool you are using actually allow you to get to the feed rates you are programming. A widely varying chip load, or one that is too low or too high, will quickly wear out the tools.”

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.

With all these cutting tools on display, it was difficult for any one cutter to stand out, but Harpaz’s excitement for barrel-style cutters was especially high.

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.

Morrison said, “A through-coolant system that is constant and consistent can maintain the heat absorbed by the insert at a fairly stable range to avoid thermal shock. Always use a clean, quality coolant and consider its oil concentration percentage.”

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

Ingersoll seems to take this claim seriously, as it introduced multiple indexable barrel-shaped cutters to serve this niche:

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

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."

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.

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

Easily access valuable industry resources now with full access to the digital edition of Canadian Fabricating & Welding.

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.

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.

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.

Sue Roberts, associate editor, contributes to both Canadian Metalworking and Canadian Fabricating & Welding. A metalworking industry veteran, she has contributed to marketing communications efforts and written B2B articles for the metal forming and fabricating, agriculture, food, financial, and regional tourism industries.

Keep up to date with the latest news, events, and technology for all things metal from our pair of monthly magazines written specifically for Canadian manufacturers!

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

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

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At a recent event announcing its latest product lines, Ingersoll Cutting Tools made one thing clear: it sees high-feed machining as the future of metal manufacturing.

High tool loads, especially in milling, bring out a system’s weakness. That weakness could be a poor rigid setup, a weak machine tool, or a loose bolt in fixturing that causes vibration. Machine tools are pushed to their limits for HSM, so the fixtures and tools have to be absolutely rigid to withstand the loads.

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.

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!

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.

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 DiFeedWinV, for example, is a 90-degree indexable end mill designed for the die/mold industry. Based on the existing DiPosFeed line, it is designed for milling in deep cavities, but Harpaz says the V-shape of the insert pocket provides even greater rigidity and enables even higher feed rates than the DiPosFeed line.

“At higher speeds tool balance is exponentially more important as inertia begins to affect the tool, causing a compound problem of runout and imbalance that can even damage the machine spindle,” Morrison said. “Toolholder design also needs to be considered. Not all clamping systems will maintain their gripping force at a high rotational speed.”

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.

JD Machine, 2024’s Top Shops Honoree in Human Resources, embodies its “Education for Life” core value with a robust apprenticeship program and significant continuous improvement efforts.

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

Pairing a shoulder mill with a five-axis machine has cut costs and cycle times for one of TTI Machine’s parts, enabling it to support a niche racing community.

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.

Ingersoll has fully embraced this machining strategy, announcing the release and updates of dozens of high-feed cutting tools in many sizes over the course of the evening. Dubbing these new high-feed options the WinSFeed line, it combines the tool life of the SFeed material grades with high-feed geometries.

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

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.

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

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.

“Barrel finishing lets you finish with four times the step height,” Harpaz says, “saving 75% of passes.” He goes further: “I predict that the ballnose will disappear.”

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

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.

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.

Harpaz discussed both solid-carbide barrel-style end mills and indexable milling tools that emulate the barrel-shaped profile, praising both for enabling shops to dramatically increase production speed over ballnose end mills. “We are in love with the barrel because the barrel is so fast,” he says.

“The appropriate coatings will depend on the material being cut and the geometry of the insert,” said Pollock. “The geometry of the insert may require that the coating be very thin. And the thinner coating is typically better at heat resistance. A thicker coating will undergo more thermal expansion and doesn’t behave as well when heated—it can’t expand and contract as completely as a thin coat.”

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.

Successful use of HSM depends on how the machine is programmed, how the tooling is used, and the tooling itself. Tools need to be designed for the higher speeds.

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.

Barrel cutters — also known as circle-segment cutters — are end mills with conical shapes designed to replace ballnose end mills in five-axis machining applications, especially in the aerospace and die/mold industries. They are known for large stepovers that dramatically improve cycle time, which is why Harpaz believes they will only grow in popularity.

According to Harpaz, 75% of the cost of making a part is fixed, with the largest variable cost being the time to machine the part. That makes reducing production time the most effective way to reduce the cost of a part, which guides Ingersoll’s cutting tool designs.

The heat zone of a coating needs to be matched to what the tool is doing. Too much or not enough heat generation can cause a problem. Morrison said, “If the coating has a very low coefficient of friction, operations such as tapping may not generate enough heat to get the chip to break efficiently. The low heat level can create the tinfoil effect where the chip cannot break. Eventually chips build up in the hole and break the tap. If the coating cannot handle the heat generated by the operation, such as a high-feed mill, then it will break down quickly and expose the tool substrate, which will yield poor tool life.”

“Shoot for stability, and use a tool for the process it was designed for,” said Cullen Morrison, business development manager, threading and milling, at KOMET of America. “One thing to consider is optimizing the tool design. Inserts with a large nose radius are better suited for high feed rates and heavy stock removal but are prone to chatter in small depth of cut, light feed rate finishing applications. If you are taking a large depth of cut with a small nose radius, it is likely to change the way the forces act on the insert and you may get chatter.”

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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.

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

With nearly every tool discussed, Harpaz emphasized the shallow depth of cut and constant feed rate, hammering home the company’s confidence in high-feed milling. He even advised using the higher tool life of the lines on display to push the cutting tools even harder. “It’s not about saving tool costs, but reducing production costs,” he says. Doing so reduces the tool life to what might be expected without the treatment, but increases productivity and therefore profitability, in his opinion.

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

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

“If coolant is needed, there are several application-specific delivery options such as axial coolant lines and coolant channels that come out at the cutting edge.”

Tools for high-speed machining need to be rigid and as short as possible to avoid chatter or deflection. Photo courtesy of Walter USA.

High-feed machining is a machining strategy that uses chip-thinning cutting tool geometry to enable exceptionally high feed rates, typically with a high lead angle and shallow depth of cut. Machinists using this strategy have been able to both increase productivity thanks to the higher metal-removal rate and increase tool life thanks to the constant chip load of high-feed toolpaths.

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As with all applications, tool material and length-to-diameter ratio also affects HSM success. Morrison said that steel body tools are good to 3x or 4x diameter depending on the load. Carbide tools are better for HSM applications requiring a longer reach. Dampened steel tools can cut even further because they absorb vibrations happening at the cutting end.

High-speed machining (HSM) shaves time off metal removal processes. Low speeds and feeds that remove a large amount of material are replaced with light depths of cuts made at high feed rates. Metal is removed quickly, and the resulting near-net-shape parts, with surface finishes often from 10 to 12 RMS, reduce the semi-finish and finish operations.

Like the high-feed milling options, these barrel cutters lean into newer approaches to machining that promise to dramatically improve productivity. Clearly, Ingersoll hopes that its tooling combined with these machining strategies will enable shops to stay competitive in the modern metal manufacturing marketplace.

The New Product Rollout showcased dozens of new and updated cutting tools, with high-feed machining as one of the major highlights. According to Jacob Harpaz, the benefits of this advanced machining strategy will only increase its popularity with shops. Photo Credit: Ingersoll

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

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

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“Tool manufacturers are adding tapered necks to some of the carbide tools, especially for the mould and die industry, so you have a stronger tool for a longer reach and the shanks of the tool will not rub the side walls of the mould cavity,” said Ball. “Those tapers increase strength by 10 to 20 per cent and give you the clearance to use a shorter, stubbier tool.”

Tool balance is important when running at high RPMs. Most common tool designs with tool holders will work without a noticeable problem at speeds less than 7,000 to 8,000 RPM. But, over that speed, Morrison said you can start to see runout problems and decreased tool life.

“Holders are critical for maintaining long, consistent tool life. It’s common for shrink fit holders to be used to hold the tight tolerances, but I also see the industry moving toward high-precision milling and collet chucks, as well as hydraulic chucks.”

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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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.

As with most processes, the application determines the best tooling to use, but some rules of thumb should be considered for any HSM job.

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

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The event saw dozens of new cutting tool options, including numerous high-feed machining inserts, modular milling options, drills, and tools for turning, parting and grooving. Photo Credit: Ingersoll

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

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?

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.

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

“Another method would be to engage a small percentage of the tool diameter so you get the chip thinning effect that allows you to elevate speed rates. The roughing inserts--and HSM is basically a roughing process--have to have a stronger edge and tougher coating than the finishing inserts.”

Luke Pollock, product manager at Walter USA, described a high-speed mill tool: “A common HSM mill tool uses a triangle-shaped insert with rounded edges. It is positioned in the cutter with a high lead angle, which allows the tool to take advantage of the chip thinning principle. As the tool is advanced, you get a chip thickness that is smaller than the advancement of the tool. For example, a 0.003-in. chip thickness is produced rather than the 0.005 in. that tool was advanced. These two values would be equal for a tool with a 90-degree shoulder.

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

Pollock said, “Sometimes air is adequate, but if it isn’t we prefer to use coolant just for getting the chips out of the way.”

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.

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

Hertel Metalworking Products - ball nose insert milling cutter

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