High-Feed Machining Dominates Cutting Tool Event - center milling insert cutting tools

 2024-06-26 04:26:43

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.

Any shop that chooses to hog out mold and die cavities with a solid carbide ball mill could be missing out on throughput gains available with new indexable mills, according to Ingersoll Cutting Tools (Rockford, Illinois). In fact, shops that have made the change-over have reported gains of as much as 3 to 1 in roughing and 6 to 1 in finishing, the company says. Many report improved surface finishes as well.

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.

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.

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.

Typical parameters for the shop’s previous cutter, a ¾-inch carbide ball mill, were 30 ipm, 1,250 rpm and a 0.01-inch cutting depth with stepover ranging from 0.03 to 0.05 inch. In contrast, the Chip surfer enabled increasing the standard feed rate to 50 ipm and significantly reducing stepover. As a result, the metal-removal rate doubled. “The as-machined finish is good enough to completely eliminate polishing,” says C-L programmer Buddy Walston. “Remember, the parts we make aren’t particularly appearance-sensitive.”

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.

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

B&J Specialties uses Ingersoll’s high feed bullnose Chip Surfer to hog out a cavity in a wrought mold block at 700 ipm, compared to 80 ipm with the shop’s previous ballnose mill. Despite the higher material removal rate, edge life per unit of material removed more than tripled.

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.

“This recognition highlights the importance of material and process development along with systematic work in grade development for success in metal cutting”, says Emmanuelle Göthelid.

The following provides a closer look at the Chip Surfer and how these shops have employed the tool to realize these advantages in their cavity milling operations.

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.

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

Ballnose mills are a common choice for hogging out cavities on molds and form dies. However, these three shops have realized significantly faster cavity milling by switching to Ingersoll’s Chip Surfer modular tooling system, which features a cylindrical shape that keeps more of the tool engaged in the cut.

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.

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.

“Many of the new indexable tools capitalize on the fact that cavity hogging is largely side milling, explains Bill Fiorenza, die and mold tooling manager at Ingersoll. “Generally, indexable form tools are more cylindrical than spherical, so more of their active surface is moving at optimum surface cutting speed. This is not possible with spherical mills because surface speed varies with diameter.”

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.

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.

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

The development of a steel milling grade designed to give the customer a long insert tool life and stable production led to the award of the “Wilhelm Haglund Medal to the Product Developer of the Year” in 2018 to Karin Andersson, Björn Ericsson, Emmanuelle Göthelid and Marie Pettersson from Sandvik Coromant. The medal was presented in conjunction with Sandvik’s 2018 Annual General Meeting.

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.

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.

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

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

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.

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.

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

Additionally, the ductile alloy steel shaft makes the tool more forgiving of vibration and high side loads, especially during interrupted cuts. At B&J, Crosby-Levus and Datum, this has eliminated the need to slow down around corners and internal curves — features that all three shops cite as constituting a large portion of the cycle time on a typical mold or form die.

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

Rob Guiao, Chris Hall and Bassanio Peters will demonstrate relatable situations to equip you with data to improve predictability, future-proof operations and maximize ROI. Agenda: Explore the importance of data in decision-making, especially for facility upgrades or new projects Learn how comprehensive solutions for manufacturing and construction projects can improve predictability and ROI See real demonstrations of machine integrations, facility layouts and automations to ensure proper throughput and integration

The shop also reports a 25-to-1 gain in tool life, and it has eliminated semi-finishing operations. Another Chip Surfer tip, the bullnose, has replaced EDM for roughing pedestal punches. Using the tool to mill these parts to within 0.02 inch of final size has reduced cycle time and eliminated a second setup.

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.

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

A key point is that speeding cavity milling isn’t just an end in and of itself. Cavity work makes up a large portion of the cost of producing molds and form dies. The shop that speeds up this operation can quote faster delivery times and lower prices while still maintaining profits, Mr. Fiorenza says. Likewise, captive die shops can turn around repairs much quicker, thereby delivering its forgings or stampings sooner.

Crosby-Lebus supports a forging operation that turns out parts for giant cranes. A typical forging is a rugged, 200-pound crane hook. Much of the machining here consists of repair work on hardened dies. The shop has standardized on a ¾-inch Chip Surfer high feed cutter for die gutters and flash lands as well as cavities.

As evidence for these claims, the company cites the experiences of three shops: B&J Specialties (Wawaka, Minnesota), Crosby-Lebus (Longview, Texas) and Datum Industries (Grand Rapids, Michigan). All have switched from ballnose mills to Ingersoll’s Chip Surfer, a modular tooling system consisting of a ductile alloy steel shaft and a variety of replaceable, hard carbide cutting tips.

With the Chip Surfer’s toroidal high feed tip in place, the shop roughs the cavities at 200 ipm, 3,750 rpm and an 0.012-inch cutting depth. That’s an 8-to-1 gain in throughput compared to the previous ball mill, which ran at the same spindle speed but only 100 ipm and an 0.004-inch cutting depth,

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).

The combination of the cemented carbide, coating, preparation and finishing is what leads to the characteristics of a cemented carbide grade and the challenge is to find the right balance between the components.

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?

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.

Datum first tried the Chip Surfer high feed mill on a narrow, deep cavity that created problems for its ball mills. These tools always left a bump at the bottom of the cavity, necessitating additional operations to smooth it.

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 GC 1130 uses a fine-grained cemented carbide with a high content of chrome together with a layer made with Zertivo™, Sandvik's unique production technology for PVD grades. This technology enables increased control over the manufacturing process, which is then carefully adapted to the grade-specific requirements. The result is a more stable product with longer cutting life, for increased customer benefit.

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

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.

As shown here, the Chip Surfer bullnose and toroidal cutters feature a more straight-sided profile than the conventional ballnose mill. With no “nose,” the cutting radius, and thus, the surface speed, is more uniformly optimum over the entire cutting area. Additionally, the tool’s corner radii, sweeps and backdraft combine to improve free cutting, reduce cutting forces, capitalize on chip thinning and better clean out deep corners.

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.

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

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.

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."

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

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.

Putting the carbide only where it’s needed—at the cutting edge—reduces tool costs, the company says. A single shank can accommodate the full range of replaceable tips, which can be quickly changed out while in the spindle at 0.0005-inch repeatability. “You can replace worn tips or switch from roughing to finishing tips without losing datum,” Mr. Fiorenza notes.

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

At the seminar, representatives from multiple companies discussed strategies for making orthopedic devices accurately and efficiently.

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.

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

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

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.

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.

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.

Using the Chip Surfer’s toroidal high feed tip, the shop increased cavity roughing feed rates from 100 to 200 ipm and cutting depth from 0.004 inch to 0.012 inch (both the Chip Surfer and the old ball mill ran at a spindle speed of 3,750 rpm.) That’s an 8-to-1 gain in the corners as well as the straightaways. For finishing, the shop switches to a bullnose tip—a simple, 20-second operation performed while the threaded shank is still in the spindle—and increases the feed to 700 ipm. The next tip picks up where the previous one left off, within 0.0005 inch. Additionally, the shop has found that repeatability among tip is sufficient to eliminate the need for offsetting or touching off.

In contrast, the new tool leaves the bottom completely flat and completes the slot in one-third of the time. Of course, the benefits extend beyond that specific job. Since retooling, the shop says it has been able to feed 10 times faster for all cavity work. Standard settings are 400 ipm, 3,855 rpm and an 0.2-inch cutting depth. “The most pleasant surprise is the speed in and out of corners,” says process engineer John Smith. “We don’t have to slow down, and we are left with a square corner and a perfectly flat bottom.”

“It´s a great honor for us. Words can´t describe the feeling of being chosen for this year's Wilhelm Haglund medal, but unreality and pride are closest to hand, given the high level of the other nominated products”, says Emmanuelle Göthelid.

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

This new quick-change tooling system enables shops to get more production from their Swiss turning centers through reduced tool setup time and matches the performance of a solid tool.

The primary key to the Chip Surfer’s effectiveness is its cylindrical geometry, which leverages chip thinning and places more of the active cutting surface near the full radius to cut at optimum speed, the company says. This aids in producing square shoulders and flat, bump-free bottom surfaces. In contrast, the only part of a spherical ball mill engaged in cutting action is its equator.

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.

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

“Innovation and constant product development are crucial for our continued success. The fact that GC 1130 is about to be the best selling cemented carbide grade in Sandvik Coromant's product family for mills is a tangible example of the link between investments in innovation and business benefits”, says Sandvik's President and CEO Björn Rosengren.

B&J Specialties focuses on large mold sets for appliance and automotive manufacturers. Typical materials machined here include hardened A-2 stock as well as wrought H-13 and M-4 steel. The shop’s workhorse CNC machine is a Makino V 550 with a 20,000-rpm spindle and table speed to spare. In fact, before changing tools, the shop had to slow things down to avoid dulling or snapping its carbide ball mills every 10 minutes.

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

Join Mahr for an informative webinar to discover the latest advancements in precision measurement, designed to elevate your quality assurance processes and unlock peak productivity. It'll explore cutting-edge technologies — such as modern height gages and contour measuring systems — along with their applications, benefits and technical capabilities. Discover the power of height gages: Learn how intuitive and sophisticated height gages can revolutionize your measurement processes, enabling quick and accurate results in inspection and production areas. Explore the practical functions and ease of use that make height gages an ideal solution for manufacturers seeking high-performance and reliable measuring technology. Examine sample applications and industries where height gages excel, such as qualifying first parts, inspecting incoming parts and measuring series of parts in industries like aerospace, automotive and medical. Unlock efficient contour measurement: An introduction to the latest contour measuring technologies that enable fast, simple and comprehensive contour measurement in the production environment. Discover how these innovative solutions ensure reliable measurements, saving time and increasing efficiency while measuring a wide range of workpieces. Learn how to streamline your contour measuring process with speed and simplicity, achieving fast and precise measurements with incredible versatility. Register now and discover how to unlock peak productivity with new innovations in precision measurement. Agenda: Insights into the latest precision measurement technologies and their applications Understanding of how to improve quality assurance processes and increase productivity Knowledge of how to select the right measurement solutions for your specific needs Tips on how to optimize your measurement processes for maximum efficiency

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

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.

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

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

The cemented carbide grade that led to the win for Emmanuelle Göthelid and her colleagues is called GC 1130, is developed for steel milling and has a coating using the PVD-technique (Physical Vapour Deposition).

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

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

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

The Chip Surfer’s geometry has enabled Crosby-Lebus to complete forging die repair in half the time taken with its previous, ballnose mill. No reduction in surface speed is experienced at the tool tip because unlike a spherical mill, the radius never goes to zero.

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

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

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

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

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.

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

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.

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.

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!

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.

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.

“Many programmers brought up on ball mills slow down in the corners out of habit, or they’re afraid of snapping the tool due to higher lateral loads or chip jamming at that point in a tool path.” Mr. Fiorenza says. “Not so with John Smith. He capitalizes fully on a tool geometry that favors the “feed fast, cut shallow” strategy, and he practices it everywhere possible—even in the corners and internal curves. The results speak for themselves.”

High-Feed Machining Dominates Cutting Tool Event - center milling insert cutting tools

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