How to identify Carbide Insert? - Lets Decode the Mystery ... - iso turning insert chart

 2024-08-12 10:56:35

This software-centric technology aims to facilitate the connection between a robot and various other key elements of an automated, machine-tending process.

Recent testing has shown that thread rolling can be more economical than thread cutting when producing 4,000 parts or more. A newly created calculator can help you to determine which might be the better option for your threading applications.

A multispindle platform designed to combine the high production speed of a cam-driven machine with the precision and repeatability of CNC also includes technology to speed set ups for new jobs.

Titanium is an extremely potent solvent. It forms very stable bonds with oxygen, nitrogen and carbon. That means, given the right environment, titanium will rapidly degrade any areas of a cutting tool that are in contact with it that contain oxides, nitrides or carbides. All of these are elements of carbide cutting tool coatings and substrates.

In addition, the insert coating needs to possess low-friction qualities to reduce heat generation and abrasive wear while preventing material deposition, known as built-up edge. It also needs to retain hardness and chemical stability at elevated temperatures, and feature an outer layer with titanium-based chemistry. Traditionally, one would not expect that the appearance of the machined material in the contact layer of the coating is a good thing, but with titanium it is a basic requirement of preventing aggressive chemical wear. TiAlN is quite popular, but PVD coatings such as those used on G-9610 are a new alternative to provide hot hardness, lubriciousness and chemical stability during titanium machining.

Over the past year, Mike Gresen has led his team through the process of opening a new Benchmark Electronics location without interrupting supply to customers and within the company budget, shutting down production for only three business days.

It's important to remember that the ISO designation system is not a system that standardizes the quality of the toolholders.

This leading manufacturer of non-lubricated robotic gears uses a seven-axis turn-mill to machine components from “amorphous” metals such as bulk metallic glasses.

PMTS 2023: The Mazak Syncrex series comes in four bar capacities, ranging from 20 to 38 mm, and is available in 7-, 8- and 9-axis configurations as well as a 9-axis model with full B-axis contouring.

Production Machining’s September 2024 technology showcase includes some of the latest technology from Expand Machinery, Paperless Parts, Monaghan Tooling Group, Walter USA and more.

In addition, titanium’s thermal conductivity is famously low among metals. It is so low that most of the heat generated in the primary shear zone as a result of chip formation remains in the chip. The heat is then transferred to the cutting tool through the amount of contact area between the chip and the tool. Another consequence of the low thermal conductivity is that almost none of the heat that is otherwise quite useful in metal cutting is propagated ahead of the cut. In other words, none of the typical benefits (plasticization, local reduction in yield strength, lower cutting forces and reduced wear) are realized, while all of the disadvantages (softening of the cutting tool and reduced energy barrier for chemical reactions) are experienced.

As he progressed to CNC Swiss lead and later to his current position as CNC Swiss production supervisor, Darrin Baker helped the Swiss department at Liberty Precision double its productivity, according to his nominator.

Strain hardening (also known as work hardening) is inescapable in titanium machining. Any machining operation will leave behind a dislocation-rich surface with higher apparent hardness than the material immediately below it. Subsequent machining needs to account for this effect by making use of high-feed geometries, decreasing or increasing lead angles (depending on the convention of measurement) or, ideally, using round inserts engaged at or below a 45-degree lead to reduce the incidence of notching. Round V-bottom or RCMT-style inserts tend to be the shape of choice and are stocked with various chip forms geometries in the G-9610 grade.

This parts cleaning company is elevating its efforts to become a technical cleanliness expert, which presents an exciting, yet sometimes arduous, journey. The ongoing education of the team as well as significant investments in equipment and processes attribute to this shop’s success.

Production Machining’s September 2024 technology showcase includes some of the latest technology from Expand Machinery, Paperless Parts, Monaghan Tooling Group, Walter USA and more.

The G-9610 insert grade is said to deliver a 25% increase in material removal rate and up to 100% increase in tool life versus other grades when machining titanium. A variety of insert and chip-form geometries are available.

Machine tools capable of performing multiple functions and machining parts to completion are becoming the standard rather than the exception. Incorporating automation into these systems allows for extended periods of operation without the need for operator intervention.

The ISO designation system for toolholders for turning applicationsFor turning toolholders, as for indexable inserts, there is a similar ISO designation system.The system is designed so that each important feature and dimension of the toolholder is shown using a code system. This becomes the name of the toolholder. This system has several advantages:Unique naming of a toolholder (supplier independent)All important features and dimensions are clearly stated in the nameSome code positions relate to the insert that can be used in the toolholder It's important to remember that the ISO designation system is not a system that standardizes the quality of the toolholders. Here is an example for external turning toolholders (metric) ISO standards Turning Here is an example for internal turning toolholders (metric) Do you want to know more?Contact Us Inline Content - SurveyCurrent code - 5fce8e61489f3034e74adc64

New part programming developments continue to be added to the Tri-County Technical College curriculum and solutions for Swiss-type lathes might soon be included.

The Precision Machining Technology Show is a great example of discovering ways shopfloor employees can become more efficient, thereby helping shops become more profitable.

ModuleWorks and Toolpath announce a technology partnership that intends to utilize intelligent cloud-based manufacturing solutions for machining estimation and CAM automation.

Production of micro threads can be challenging, but using the most suitable tools for a given application can simplify the task.

Iron is, by mass, the most common element on Earth, right in front of oxygen, forming much of the Earth's outer and inner core

SolidCAM aims to align its product development and customer engagement strategies to address the evolving needs and challenges of the manufacturing industry.

Having strategies in place for managing chips is an important part of protecting the production process, from tool life to product quality.

Zeiss Quality Innovation Days brings together quality and metrology experts from all over the world to take part in industry-specific sessions.

These spindles available on Tschudin CNC centerless grinders are designed to minimize the heat transfer factor while optimizing dimensional stability and material removal rate.

In addition, tool wear when machining titanium is nonlinear. As a result of wear, hones get larger, the insert coating gets thinner and the microgeometry changes shape, all of which leads to higher cutting forces and heat which accelerates wear. Wear begets more heat which begets more wear and that creates a feedback loop that, in titanium alloys, can run away quickly and lead to catastrophic failure. It is important to monitor wear and index the cutting tool before it reaches a critical point where the stresses can no longer be sustained and the tool fails.

Can increasing productivity and reducing carbon emissions go hand-in-hand? For its high-volume machining customers, Sandvik Coromant offers a tool for data collection and comparison to aid sustainability-minded process decisions.

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

Production Machining’s August 2024 technology showcase includes some of the latest technology from SW North America, Tsugami, Siemens, Select Manufacturing Technologies, Hurco and ECI Software Solutions — all on display at IMTS 2024.

In this case, new controllers for two coordinate measuring machines — one 26 years old — with new programming software offers the possibility to enable multisensor inspection of critical, turned aerospace components.

Greenleaf’s G-9610 is a PVD-coated carbide grade designed for turning titanium-based alloys. The wear-resistant, chemically stable and lubricious coating is said to protect the heat-resistant, submicron substrate and enable higher speeds and extended tool life in continuous cuts.

By using a tool monitoring system, shops can save costs associated with machine maintenance and downtime for tool changes while increasing cutting performance.

Environmental factors. Coolant needs to be delivered in large volume and ideally at high pressure as close to the cutting edge as possible. Coolant delivered at 80 bar or higher is recommended to drive a wedge between the rake face of the cutting tool and the chip to further reduce heat transfer and abrasive wear. High-pressure or ultra-high-pressure coolant also enables increasing cutting speeds, thereby improving productivity. Inadequate coolant delivery will greatly reduce tool life.

Founded in 2001, PMTS reconvenes in April 2025 to celebrate its 13th biennial event for precision machining pros. Mark your calendar now and plan to join the precision machined parts community when we once again gather in person to share challenges and insights, see new technology solutions and learn about process innovations – everything you need to take back and immediately put to use in your own shop. __PRESENT

The Metalnox line of solvent products are designed to improve reliability and increase the ease of cleaning in vacuum and vapor degreasing processes.

Rotary transfer machines remain well-suited for high-volume production, but are now more accommodating to smaller batch sizes.

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

Finding a way to fixture contoured marine propellors proved to be this shop’s biggest challenge in developing an effective automated machining and turning cell.

Individual elements of the machining process such as machine tools, tooling and even CAD/CAM software play a role in overall machine shop sustainability. Observing the entire process especially when it comes to their influences on energy usage is key.

Note that while the information above is applicable to achieve clean, continuous turning of titanium-based alloys, milling or interrupted turning, or the removal of forging scale, might bring additional challenges.

A CNC Swiss production supervisor took to LinkedIn to describe how he discovered a rotary parts collector in the pages of our publication and has since purchased and benefited from it.

A multispindle platform designed to combine the high production speed of a cam-driven machine with the precision and repeatability of CNC also includes technology to speed set ups for new jobs.

MachineMetrics uses data synchronization and real-time monitoring of production to help keep schedules current and to reflect actual shopfloor conditions.

The SLV901 and SLV803 solvents are formulated to maintain cleaning efficacy while providing a safe, environmentally friendly alternative to processes that use PFAS and HFCs.

These spindles available on Tschudin CNC centerless grinders are designed to minimize the heat transfer factor while optimizing dimensional stability and material removal rate.

Mike Medeiros, production manager at North Easton Machine Co., has been advocating CNC Swiss lathes for years, attempting to persuade his local high school’s administration to add the technology to the school’s machining program. Finally, his efforts paid off.

The insert micro-geometry (hone and land) and macro-geometry (chip-forming geometry) need to perform very high shear cutting. Large negative lands or hones will generate significantly higher stresses and heat, which will drastically reduce tool life. The chip form geometry also needs to direct chip flow in such a way as to minimize the contact area between the chip and the rake face of the cutting tool and, thereby, the interface of heat transfer. The chip form geometry should be as sharp as it can be while maintaining sufficient edge strength to withstand the variation in cutting forces inherent in machining titanium at common cutting speeds (below 450 sfm). As the primary objective is reducing cutting forces and heat generation and transfer to tool, increasing flank clearance and reducing rake angles is hugely beneficial. As such, an RPGN insert will have appreciably better wear than an RCGN, despite the seemingly insignificant 4-degree difference in flank clearance.

Cutting conditions. The cutting speed has the greatest effect on tool life because it has the greatest effect on heat generation. In fact, increasing the feed rate is preferable to increasing the depth of cut. That’s because it produces a thicker chip, with the bulk of the heat carried within the chip shielded from transfer to the tool by the chip’s outer layers (because of titanium’s low thermal conductivity). And, while the contact area between the chip and the rake face of the cutting tool will increase as a result of increased feed rate, this relationship is not linear. Increasing the depth of cut, on the other hand, results in a proportional increase in contact area between the chip and the rake face of the cutting tool, leading to a proportional increase in heat transferred to the cutting tool. It’s best to keep the depth of cut low and instead increase the feed rate as long as the cutting forces don’t exceed the strength of the cutting tool and are well supported by the part, fixture and machine.

This 2023 Emerging Leader developed a product in response to a call for help from Yamaha that was a huge hit in the snowmobile industry when it hit the market in 2010. In fact, it is now a common product that most snowmobile OEMs have implemented.

European manufacturers may have a different balance of markets than their U.S. counterparts, but the practical challenges they must overcome are often similar — as are the solutions.

Ecoclean’s Acoustic Performance Measurement (APM) system provides in-line measurement of ultrasonic frequency and power in fully automated immersion cleaning systems on a batch-by-batch basis or at defined time intervals, such as once a shift, day or week.

Identifying and preventing these manufacturing sins will reduce or eliminate unnecessary waste, improve efficiency and productivity as well as protect profitability and cash flow.

The system is designed so that each important feature and dimension of the toolholder is shown using a code system. This becomes the name of the toolholder.

Numerous difficulties inherent to turning titanium-based alloys stem from their metallurgical properties. Therefore, it is important that CNC machine shops understand such characteristics as described below before making tooling and machining choices as they endeavor to develop an effective titanium turning process. These characteristics are chemical stability, minimal heat generation/transfer, and the ability to carry varying mechanical stresses.

Here are some tips for choosing, maintaining and customizing a granite solution that will best meet your shop’s particular inspection needs.

MicroCare offers alternatives and expertise for replacing 3M Novec vapor degreasing fluids which are being discontinued, including fluoropolymers, fluorinated fluids and PFAS-based additive products.

Superb critical thinking, top-notch leadership skills and a passion for building a strong team are a few of the common traits held by this year’s five Production Machining Emerging Leader award winners.

Effective titanium turning requires the proper selection of cutting tools and machining processes to mitigate the effects of the material’s unique chemical and physical properties.

ModuleWorks and Toolpath announce a technology partnership that intends to utilize intelligent cloud-based manufacturing solutions for machining estimation and CAM automation.

Now representing six brands in North America, Platinum Tooling offers tooling and related accessories for a range of machine tool types, including CNC mills, lathes and Swiss-types.

Many view quality control as such, but integrating new measurement technologies and approaches can ultimately minimize QC’s impact on throughput and a company’s bottom line.

High-speed spindle technology was key to effective milling of small cardiac monitoring components complete on a CNC sliding-headstock machine platform instead of running them across two mills.

ModuleWorks and Toolpath announce a technology partnership that intends to utilize intelligent cloud-based manufacturing solutions for machining estimation and CAM automation.

The machining environment needs to be rigid and damped. If any part of the environment (part, fixture, tool or machine) responds positively to the high-frequency periodic forcing intrinsic to titanium chip formation, users will quickly run into constructive interference which, in this case, is rather destructive overall. The result can be fighting an uphill battle against vibration and all the damage that it brings, including but not limited to accelerated and irregular tool wear, poor surface quality, spindle stall, and inadequate function and accelerated wear of the guides and bearings. A general tip for countering vibration is to vary the cutting speed with time, within a -5% to +5% window. This prevents the buildup of constructive interference by continuously varying the frequency of the forcing function and should limit vibration to a minimum. A larger (±10%) window might be necessary or a smaller (±3%) window could be sufficient.

As a result, stable and efficient turning of titanium requires selecting or designing cutting tools and machining processes to mitigate the effects of these properties. This includes careful consideration of:

This shop finds value in using an indexable-insert-style broaching tool to create blind-hole slots in heat-treated Inconel aerospace parts on a CNC lathe.

High-pressure coolant that is efficiently applied to a cutting tool will enable faster, more precise cuts; prevent oxidation of the tooling and workpieces; and prolong the life of a cutting tool.

SmartBox 2.0 integrates advanced communication protocols and edge computing for enhanced productivity and security, ensuring safe data export from machines to factory networks.

At EMO 2023 in Hannover, Germany, FANUC presented an automated manufacturing cell simulating the complete production and measurement of aluminum electric vehicle (EV) inverter cases.

PMTS 2023: Dayton Coating Technologies utilizes a distinct cleaning system to promote proper pretreatments for all parts before the coating process.

At EMO 2023 in Hannover, Germany, FANUC presented an automated manufacturing cell simulating the complete production and measurement of aluminum electric vehicle (EV) inverter cases.

This century-old manufacturer is a case in point of how company culture and openness to adopting new technology paves the way to success.

PMTS 2023: This tool management solution with Optik software is designed to help shops increase production output and decrease human error.

Production Machining’s June 2024 technology showcase includes some of the latest technology from Siemens, Ceratizit, Walter, Kennametal and more.

Participants who pass the program quizzes earn a certificate of successful completion, as well as 4 hours of continuing education credit from Sam Houston State University.

I recently learned about a 153-year-old manufacturer that has produced billions upon billions of precision, metal pins which started another business making one-off wooden baseball bats. (Like I asked it to do for me and you’ll see at this year’s Precision Machining Technology Show). Here I explain why it’s worth the time to read that article.

The Top Shops 2024 survey for the metalworking market is now live, alongside a new homepage collecting the stories of past Honorees. This year's survey ends April 30, though.

Tooling selection. For rough turning, the insert substrate must have enough toughness to endure the chip formation mechanism and sufficient strength and hot hardness to maintain a sharp edge for as long as possible. Fine- or medium-grain carbide grades with low binder content are best. For finishing, the benefits of higher hot-hardness outweigh the need for elasticity and toughness meaning a submicron grade (also with low binder) would give the best results. This is exemplified in Greenleaf’s recently developed G-9610 grade, especially when paired with the TF chip form geometry, which has demonstrated high turning productivity and tool life.

PMTS 2023: The InchMax Series includes 2- and 4-flute square end mills which feature Union Tools’ UT coating and its standard Super Micro Grain carbide and tolerances.

The Production Machining media brand covers advanced new technology, practices and processes in the manufacture of precision machined parts in high volumes. About Us

Production Machining’s September 2024 technology showcase includes some of the latest technology from Expand Machinery, Paperless Parts, Monaghan Tooling Group, Walter USA and more.

Finally, titanium is very ductile and goes through a large region of elastic and plastic deformation before finally fracturing to form a chip. Once the fracture starts, elastic deformation is recovered and the deformed layer springs back, resulting in a great degree of variation in cutting forces per revolution — even in continuous cuts. Mechanically, machining titanium is likened to machining a wet sponge. Using cutting speed parameters that current tools and machining environments allow, the chip formation is cyclical and produces a segmented, serrated chip, which tends to exacerbate the mechanical abrasion of the tool.

Many understand the advantages of thread whirling on a CNC Swiss-type. However, new tooling technology for this thread-machining process can further improve cycle times and reduce cost per part.

Join this webinar and discover how to overcome multi-channel mill-turn and Swiss CAM programming challenges using SolidCAM, with amazing machine simulation and customized post-processors tailored for your mill-turn and Swiss CNCs. Darrin Bryant, SolidCAM’s applications engineer, will highlight how to utilize SolidCAM's CAM software to enhance your CNC manufacturing and demonstrate how to optimally set up your projects for guaranteed success. Agenda: Major benefits of SolidCAM's single window integration and full associativity in Solidworks Embracing the future of increasingly complex CNC machines—including five-axis, Multi-Channel Mill-Turn and Swiss CNCs Exclusive features of SolidCAM's iMachining that provides much shorter cycle times and superior tool life Using iMachining Technology Wizard takes the guesswork out of defining cutting conditions and automatically provides optimal feeds and speeds while considering stock materials, cutting tools and CNC machine properties Using SolidCAM’s Toolkit to easily create customized precision project setups Highlighting the advantages of multiple verification options in SolidCAM Utilizing SolidCAM’s operations sequence manager to simplify synchronized part creation with fewer steps and higher success

Verisurf will offer complete metrology solutions that combine its model-based inspection and measurement software, training and live technical support with Hexagon CMMs.

Sumitomo Drive Technologies has received the 2024 National Metalworking Reshoring Award as a result of its reshoring and nearshoring strategies.

This software-centric technology aims to facilitate the connection between a robot and various other key elements of an automated, machine-tending process.

How to identify Carbide Insert? - Lets Decode the Mystery ... - iso turning insert chart

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