Maximizing MRR with Tools for High-Speed Milling - ball nose insert milling cutter

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.

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."

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!

Geisel concurs with John Stewart that the challenge for tooling suppliers is to make a strong, rigid cutting tool or insert.

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.

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

When grooving small pieces, cutting pressure tends to be relatively high. Aside from slowing feed rates, it can also help to use high lubricity coolants that work well in tight spaces.

“The VolCut insert holders provide a rough boring solution unmatched by other rough boring competitors,” says Natalie Wise, USA product manager of the Wohlhaupter boring line. “The ability to utilize the VolCut insert holders with your existing standard Wohlhaupter modular tooling provides the additional range needed to vastly improve your rough machining operations.”

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

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.

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

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.

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.

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.

“The geometries are not standardized, but there are ways to create space at the head of the tool to promote chip flow,” says Stewart. “Sometimes the actual grooving tooth on the cutting tool will have a chip breaker on it—this will help the chip move out and get flushed with coolant.”

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

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.

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

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.

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.

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.

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

“Slow feeds can be a good idea, depending on the material,” says Bokum Tool’s Stewart. “With smaller sizes a weaker tool neck will want to deflect, especially with carbide, and with increased distance to the groove, feed speeds need to be adjusted downward.”

“The cutting process produces pressure on the work piece and on the tool. Controlling the pressure during machining dictates how successful we will be [in producing an effective cutting tool]. We can control cutting pressures by controlling the width of the grooving insert; the wider the insert, the more pressure it will produce. We also grind positive rakes on the inserts to control the pressure and to act as a chip former to control the chip shape and size.”

If the chip created by the grooving tooth is wider than the finished groove, then you can minimize the possibility that the chip will stay in the groove. But when it comes to harder metals the challenge isn’t chip control so much as creating the chip in the first place. “At 1.5 mm you need to have a tool that is strong enough to create the chip,” says Stewart. “But from there, with a strong alloy like Inconel, it is relatively easy to control the chip. In the case of aluminium and softer materials, where the chip is continuous, it creates greater headaches because the material balls up.”

Allied Machine and Engineering has introduced the Wohlhaupter VolCut insert holder, which features a high cutting speed and material removal up to 2.755”.

As a result, Cogsdill’s tools are better suited to high production lines, an area that has seen some big changes of late. Only a few years ago, small bores were typically 4 mm, but now leading vendors are delivering off-the-shelf bore grooves to 2 mm, with specialty applications going much smaller. This has resulted in new abilities—and challenges—when it comes to grooving very small parts, as well as increased demand.

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

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

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.

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.

At Hurco, we believe that our machines are designed and constructed to provide our customers with superior accuracy and rigidity and serve them well for many years. Watch the video to learn more.

“The challenge with grooving is that below 1.5 mm it is difficult to make a tool that is strong enough,” says John Stewart, VP of engineering at Bokum Tool in Madison Heights, MI. “The overall determining factor is: What does a groove look like in a hole that size? If it is proportionally very similar to a larger hole then it is theoretically possible to get very small, but it really comes down to the strength of the tool itself.”

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

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?

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

“You need the chips to be able to freely get out of the bore and away from the cutting action so they do not interfere with the machining process.”

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

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

“There are companies that require face grooves with major diameters as small as 0.2 mm,” says Duane Drape, national sales manager for Horn USA Inc., in Franklin, TN. “This is mostly aluminium, but I have had customer requirements to get that small with steel at 50 + Rockwell.”

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.

“Exotic materials are not for production jobs—these are low volume applications,” says Tom Ficker, regional sales manager for Cogsdill Tool Products, Inc., with responsibility for Canada. “The problem with precision grooving in high nickel alloys is that you beat down on the grooving insert almost from the get-go.”

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.

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.

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.

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.

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

Another approach is to compress chip width, thus ensuring it doesn’t lodge in the groove and result in tool failure. Either way, when it comes to grooving small parts, the combination of slow feed rates, proper tool selection, and a strategy for chip evacuation is the best way to ensure success.

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

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.

“It is important to keep speeds as low as possible when you have small-sized parts,” says Igor Kaufmann, a member of Kennametal Inc.’s global team for turning tools. When grooving miniature parts, Kaufmann emphasizes that the tools still need to fit axially and apply radial force to the bore. As a result, it is hard to ensure that the tool is strong enough, which then leads not only to chatter issues but also challenges with breakage and chip evacuation.

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

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.

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

A frequent issue is whether or not to go with inserts or solid carbide tools. Inserts can be indexable or have only one edge for single use. Inserts tend to be less expensive, but usually can’t get into the smallest bores, and are not as strong as solid-carbide tools.

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

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.

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

“This is a double-sided insert that works well with slow cutting forces,” says Kaufmann. “The GUP insert geometry is advanced and versatile, with excellent metal removing rates.”

Allied Machine and Engineering has expanded its boring line with the introduction of the Wohlhaupter VolCut insert holder. The rough boring system is engineered to remove large volumes of material at high speeds and light feed rates in a single cut.

The problem with carbide is that reducing deflection increases the risk a tool will break, so it’s important to preserve the strength of the neck of the tool. Tool monitoring is also recommended, because with small cutting edges it can be hard to see or hear when a tool breaks.

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

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.

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.

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.

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.

Hydraulics, given their need to control pressure, create demand for inside diameter (ID) and outside diameter (OD) grooving seals and threads, as well as relief grooves. In the automotive sector, miniature grooving applications include fittings for air bags and fuel injection components.

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

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.

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

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

VolCut combines the modularity of the Wohlhaupter MVS connection with Allied Machine and Engineering’s large-diameter holemaking solution. The company says this combination saves time and offers increased material removal and chip control at greater depths for large-diameter applications — even on underpowered machines. The VolCut insert holder is stocked for quick delivery with bore diameters ranging from 2.559”–128.149” (65–3,255 mm). Its design incorporates serrations that connect with Wohlhaupter’s Twin Cutter and AluLine boring systems.

Allied Machine and Engineering recommends VolCut to manufacturers pre-machining large-diameter holes in components for the oil and gas and heavy equipment industries, saying VolCut’s high cutting speed and material removal up to 2.755” (70.00 mm) can reduce cycle times. The company reports case studies show cycle time reductions up to 80% when compared to similar circular milling applications. The indexable inserts VolCut utilizes shorten process times even further by allowing the tool to remain engaged in the spindle while changing out worn cutting edges. Allied Machine and Engineering stocks the indexable inserts as standard items to facilitate quick replenishment.

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 grades Iscar uses for our inserts depend on how fast the machine spindle can spin,” says Iscar Tool’s Geisel. “10,000 rpm sounds high but remember you are working with very small parts, around .100 in. in diameter. So that 10,000 rpm with a .100 in. diameter works out to be about 260 sfm…we need to design and produce the insert out of carbide grades with coatings that can run at such speeds.”

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.

“It would be preferable to take an indexable insert into small grooves, because it would be more economical. But you often have to go with a one piece design, using a brace tool with a carbide or carbon steel cutter brazed to it.”

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

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.

ID grooving in particular can be an issue with small parts, says Steve Geisel, senior product manager for Iscar Tools Inc., Oakville, ON.

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

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

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.

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

How best to approach grooving a small part has a lot to do with the materials involved: repeat, high volume applications tend to be with softer metals, with specialty one-offs applying to higher value applications, often with tougher alloys.

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

“If you are cutting to small major diameters on the face, where the grooves generally aren’t that deep, the chips are not an issue,” says Drape. “But in ID grooving applications where the groove is deep into a bore, then we need to get coolant in, and also need to break down the chip so it can evacuate.”

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.

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.

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.

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

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.

Diagnosing when a tool is failing is important because it sets an expectation and a benchmark for improvements. Finding out why gives us a clue for how to fix 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.

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.

“As a tooling manufacturer, we are being pushed to produce tooling able to groove in smaller, and smaller diameters. Our PICCO line can produce grooves in diameters from as small as 2 mm (.08 in.) and we can go smaller by special request.”

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

When Puneet and Neelam Neotia moved from India to the United States several years ago, they brought with them a family background in manufacturing and CNC machining. Now the couple is working to get their startup machine shop off the ground, sourcing new customers and getting the word out about their shop in Clarksville, Indiana. The couple — proud to publicize their "Made in the USA" parts — is leveraging family connections and manufacturing capabilities back in India, but not in the way that some people assume.

Solid carbide grooving tools are usually L-shaped. Part of the challenge is that even the non-cutting, or “leg” part has to fit into the bore diameter. Given that the bottom of the L, or the “foot” has to be even smaller, strength becomes an issue, as does the fact that groove depth is limited. As a result, with bores of less than 2 mm in diameter the best tools are now constrained to a groove depth of around 0.2 mm.

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

Managing chip generation in tight spaces has always been a challenge, because the smaller the hole the harder it is to get the chip out. One approach is to plum or port the tool to get coolant out. There are also advanced tools, like Kennametal’s AF-GUP insert geometry for grooving and turning, that are specially designed for these challenges.

But replaceable inserts, single edge, can still get to some small diameters. More cost effective than a solid carbide tool, they can also deliver better axial depth. That said, solid carbide tools are usually more expensive, toolholders aren’t, and there is a risk the holder might break after a dozen or so uses.

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.

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."

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.

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.

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

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!