CNC Turning Technology Targets Its Many Facets - cnc cutting insert

 2024-06-19 11:20:06

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

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

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The MB45 series is designed to deliver the low cutting force benefits of positive inserts and the fracture resistance of negative inserts.

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.

At any given time, Komarek has 40 orders in its shop for two-roll sets, of which it typically produces up to three each week, more than it was machining under the old processes.

Misapplication of these important CNC features will result in wasted time, wasted or duplicated effort and/or wasted material.

Thoughtful considerations will set you on a shortened path to the most optimized solution once cutter meets metal.

Briquettes are dense blocks created by compressing certain materials. For instance, charcoal and water softener salt are prepared as briquettes using charcoal dust and sodium chloride, respectively. These blocks can be compressed in cantilevered removable cutting rolls like those machined by K.R. Komarek, a Wood Dale, Illinois, company whose founder, Gustav Komarek, patented briquetting processes in the early 1900s to make coal less dusty and easier to transport.

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

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.

SSP’s commitment to adopting the latest machining technology benefits not only the business, but its employees as well.

“We can save hours and even days just (eliminating) the pocket grinding,” says Rammacher. “And nowadays, finding somebody that’s willing to do that day after day, it’s increasingly tougher.”

Effective team collaboration is a critical component of success in today’s manufacturing world. With cloud-based technologies that make it easy for team members to brainstorm and problem solve remotely from various locations, design-to-manufacturing processes can become faster and more efficient. This webinar will demonstrate how fully integrated CAM software can be utilized with 3DExperience SolidWorks in a seamless work environment to accelerate product development. Agenda: See how HCL CAMWorks can be used as an add-in for all SolidWorks applications working with the cloud-based 3DExperience platform Learn how fully integrated CAD/CAM saves significant amounts of time during the design to manufacturing process Gain a new understanding of how software can connect users worldwide to accelerate product development Watch a demonstration of team collaboration using platform tools in the CAD/CAM software environment

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

Until recently, Komarek’s manufacturing process relied heavily on drilling and high-speed milling to rough each roll, turning the rolls in two operations on one machine, then moving the workpieces to a horizontal mill. The shop would then hand-grind its roll pockets and rely on lengthy hand-polishing operations to achieve the necessary surface finish.

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

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.

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

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

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

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.

Tungaloy Corp. has expanded its TungMeister changeable-head endmill system. The latest addition involves a new modular head line of TungForce-Rec, miniature shoulder milling cutter series.

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.

Refined machines at EROWA are handling heavier loads, while its precision workholding enhances stability and rigidity.

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.

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.

Women in Manufacturing is excited to announce that the 2024 SUMMIT will be a hybrid event — both an in-person and virtual experience. Both program offerings will enable you to grow through education and connections that are insightful, meaningful and actionable. Join Women in Manufacturing Oct. 6-9, 2024, in Boston or digitally for an event filled with plant tours at leading manufacturing facilities, professional development sessions, roundtable discussions on important topics, and inspiring keynotes. All while engaging and interacting with peers through social and networking events! __PRESENT __PRESENT

User-friendly inspection software for CNC machining centers is shown monitoring measurements between and after machining while performing SPC based on recorded measurement values.

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.

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.

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.

In Komarek’s design, two rolls run in opposite directions while the material runs down the middle to be compacted. Materials for these cutting rolls – which measure from 12 inches up to 28 inches in diameter – range from stainless steels to alloy steels and tool steels with hardness from 25 to 40 RC.

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 addition to a versatile machine, Komarek needed durable tooling that could machine its complex roll pockets. Operations Manager David Rammacher came to Komarek from a position at Ceratizit, so he was already familiar with the company’s indexable carbide tooling. He believed that using a version of this tooling with round inserts could improve milling performance on the roll pockets.

Mitsui Seiki USA Inc. appoints Joseph Farkas as its director of sales West and Terry Ritterbush as its director of sales East.

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.

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

The insert’s large rake angle ensures a light cutting action, while the obtuse-angled flank face of the insert strengthens the cutting edge and avoids chipping. The cutter body design allows for far more compact and sturdy pockets than other cutters with flat-bottom inserts, claims the Tungaloy. Therefore, a larger core diameter is retained in the given small tool diameter, making TungForce-Rec a perfect miniature shoulder mill with incomparable rigidity for shouldering, slotting, 3D profiling, and various other applications.

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

Are AMRs the next big trend in job shop automation? System 3R’s IMTS booth will emphasize both its specialty EDM tooling and its automation products, including an autonomous moving robot.

This labor-intensive process made unattended operations impossible, which in turn meant that a single roll took three workdays to produce on a one-shift, eight-hour schedule. Even then, the manual operations made high-quality surface finishes and other specs more difficult to attain with high repeatability.

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.

After experiencing process stalls in the finishing stage of production, Bryan Machine Service designed an air-powered twin spindle and indexable rotating base to effectively double its production of small parts.

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

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.

This simple change to a Swiss-type turning machine’s toolpath can dramatically improve its ability to manage chips.

“It wouldn’t have been three going from start to heat treat in a given week,” Rammacher says. “It would’ve been maybe two. It could even be less depending on the rolls.”

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

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

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).

Thoughtful considerations will set you on a shortened path to the most optimized solution once cutter meets metal.

TungForce-Rec inserts feature a maximum 6mm depth of cut and are available in three different grades for a wide range of materials. Tool diameters are available from 8mm to 16mm.

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.

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

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.

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."

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

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

With a wide variety of briquette designs, sizes and materials, machining these rolls is a demanding task for machine tools and, in particular, tooling. To overhaul a lengthy, hands-on process, Komarek paired a Mazak turn-mill machine with Ceratizit ISO-P-grade tooling to reduce production cycles and eliminate an arduous hand-grinding process.

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

Structured light scanning is used to create a digital twin of a manufactured part, but we must understand the measurement reproducibility to best use the data.

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.

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

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.

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.

Are AMRs the next big trend in job shop automation? System 3R’s IMTS booth will emphasize both its specialty EDM tooling and its automation products, including an autonomous moving robot.

Fryer Machine Systems Inc. presents its TC Series of CNC machining centers for high-performance cutting, accuracy, reliability and ease of use.

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.

The briquette rolls Komarek machines can have anywhere from 20 to 50 pockets depending on the material that is getting compacted and the machine the roll will be used in.

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.

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

With new machining and tooling support, Komarek has cut its production steps, boosted its accuracy and repeatability, and increased overall efficiency throughout the shop. "What we've been doing is working. We're just trying to reduce costs and bring value to the customer," says Rammacher. After seeing the results of their new approach, Komarek ordered a second Integrex i-630 machining center to continue to optimize its production process.

TungForce-Rec features a V-shaped insert, designed to avoid insert movement under high centrifugal force, while delivering excellent machining reliability even when used at a high metal removal rate, according to the company.

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

Thoughtful considerations will set you on a shortened path to the most optimized solution once cutter meets metal.

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!

The Diatool Top Speed Disc features a solid reamer body with multiple connections to produce tolerance stack up.

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

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.

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?

Characterised by a highly rigid body structure and unique insert design, TungForce-Rec ensures reliable, high precision miniature shoulder milling in a wide range of materials. Now the TungMeister changeable head system has a lineup of TungForce-Rec modules. The indexable endmill system features secure coupling with minimal bending at the flange and tapered shank contacts. An optimal tool shank selection is possible from the standard shank material lineups of cemented carbide, steel, and vibration damping pure tungsten.

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

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.

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

To cut out laborious manual processes like hand-grinding, this briquette manufacturer revamped its machining and cutting tool arsenal for faster production.

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.

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.

New tech center is serving as a cutting-edge showroom and a technological hub for advanced machining applications.

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

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

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.

Ceratizit USA announces it has appointed Carlos Garza as its business development leader for the oil and gas industry sector.

Komarek now relies on some of Ceratizit’s ISO-P grades. These include HSK100 CNMG holders and CTCP135-P carbide turning tools for rough turning with interrupted cuts. For finish turning, HSK100 DNMG holders with CTCP115-P ISO-P15 wear-resistant grades provide optimal resistance to high temperatures for ideal tool life during steel machining at high speeds. Additionally, to handle milling chores, Komarek chose Ceratizit’s K2002 ball-nose indexable cutters in diameters ranging from 8 mm to 32 mm mounted in HSK100 hydraulic chucks.

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

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

The Walter Turn toolholder features rake-face cooling to help break and control chips, and double flank-face cooling directly at the cutting edge to extend tool life.

Employees who formerly would have been tackling manual tasks on the briquetting roll production line can now work in Komarek's reconditioning and repair department. These new processes also eliminated the potential for human error from hand-ground pockets, and by previewing milling paths through simulation features within Mastercam, Komarek is seeing less than a thousandth of an inch of variance in pockets. Tool life has also become much more predictable.

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.

In addition to this new tooling arsenal, Komarek brought in Mastercam and began utilizing 3D tool paths after previously relying on 2D tool paths. Rammacher says the ability to utilize more complex tool paths in conjunction with new tooling helped achieve an improved surface finish, so much so that Komarek eliminated the need for hand grinding, the most labor-intensive process in the production cycle. At the same time, the palletization abilities of their new machining center enabled them to run lights out, which lengthened their production days without increasing demands on staffing. What once required three eight-hour workdays became a one-day job.

“Now, we can predict tool life on each material," says Dan Diemer, CNC machinist at Komarek. "Our process improvements include huge gains in repeatability and reliability.”

Moving from cut tapping to form tapping for a notable application cut tooling costs at Siemens Energy and increased tool life a hundredfold.

Once Komarek added new equipment on its shop floor, the company called on Ceratizit to assist with tool-drawer setup for inventory management.

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.

Growing the company would require a smoother, more repeatable production cycle. Komarek decided to replicate its existing process as a milling operation with two setups. To achieve a surface finish of 16 Ra for all pockets, the company invested in a Mazak Integrex i-630 turn-mill machine with a two-pallet changer and modular automated pallet-stocking system. The machine incorporates an 800-mm pallet size, plus a tilting spindle and rotary table for simultaneous five-axis operations and multiple-surface machining of large, complex parts up to 28" in diameter and 27" high. With some rolls containing up to 50 pockets, a machine that could handle complex maneuvers while holding large parts was ideal for Komarek’s workload.

Attend TASC, The Automated Shop Conference, in Novi, Mich on Oct. 11, 2023 for a comprehensive look into how to use automation to transform your machine shop.

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

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.

New tech center is serving as a cutting-edge showroom and a technological hub for advanced machining 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

Not only do customers need replacement and spare cutting rolls, but briquette shapes change frequently and some jobs call for the addition of lettering or logos to the briquetting pockets. Some Komarek customers process steel, which requires a high roll hardness. Some operate on corrosives such as salt or cyanide, which can eat away at the roll material. As a result, the processed material itself, as well as the desired final shape of the briquettes, determines the specifications and size of each roll.

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.

To speed up its briquette roll production process, Komarek purchased a Mazak Integrex i-630 turn-mill machine to pair with Ceratizit tooling and machine alloy, stainless and tool steels. Photo Credit: All photos courtesy of Komarek

ANCA CNC Machines is celebrating its 50th anniversary as a global producer of CNC tool and cutter grinders.

CNC Turning Technology Targets Its Many Facets - cnc cutting insert

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