Groove or other tool geometry that breaks chips into small fragments as they come off the workpiece. Designed to prevent chips from becoming so long that they are difficult to control, catch in turning parts and cause safety problems.

Among the coatings that Scientific Cutting Tools uses for grooving tools are diamondlike carbon coatings, such as ta-C, which he describes as a very hard, thin coating that works well on tools used to cut abrasive nonferrous materials.

Modern machining relies on 5-axis technology. BAM uses the Hypermill CAM system to generate suitable NC programs – in some cases even fully automatically. (Source: Open Mind)

By standardising the special cutting geometry of finishing grooves, Horn is also responding to users’ requests for even better surface quality on the flanks and at the base of a groove or recess. The new geometry of these finish grooves has already been in use successfully for some time as a special solution for producing grooves for sealing rings and shaft seals. High surface quality is possible without any problems in the finishing process, even when the conditions are unstable. Horn offers the geometry for a variety of systems for external and internal grooving. The geometry is available as a standard tool for the 224, 229, S34T, 315 and 64T systems for precision machining of external grooves. For internal machining, it is available for the 105, 108, 111, 114 and 216 systems. Further insert types are available as special tools and can be delivered quickly via the Greenline system, whereby it is possible to deliver up to 50 customised inserts, depending on the design, within five working days after approval of the drawing by the customer.

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Some of the key features include a touchscreen interface for quick product selection, intuitive administration functions for simple stock control, enhanced rapid refill functionality for speedy and accurate restocking, customisable storage configuration for single or multiple items, a range of drawer sizes to fit the users' stock list and Wi-fi network connection capability. All of this provides manufacturers with complete control and transparency of the supply chain with full audit trails to see which colleague uses what specific cutting tools — providing a complete insight of when, where and why that product was taken from a storage solution that is secured for 24/7 access whenever you need it.

Increased productivity for short threads Suitable for universal use, the rigid tool body incorporates multiple rows of indexable inserts developed specifically for thread milling. The tool body design has been optimised with minimum spaces between the insert rows to increase productivity levels when creating short threads. The tool body and inserts are suitable for threads with a nominal diameter that starts from 20 mm and upwards with a thread pitch range from 1.5 to 6 mm and for Imperial threads a TPI of 18 to 6. This gives the new Walter T2710 Series complete flexibility for threading both metric and Imperial threads regardless of pitch and angle. 47088726 To meet the complete needs of industry, Walter has introduced several new inserts for threads from M125 to UN 5 inch, inserts with a pitch range from 6 to 10 mm and 4 TPI as well as inserts with a 55° flank angle for BSP threads. The new additions add to the already available standard insert range that includes M24 to M125, UNC1 to UN5 and G1 to G3 1/2''. The 3-edge inserts incorporate a chip breaker groove and edge geometry that ensure a smooth cutting action with minimal cutting forces. This is said to permit high cutting speeds and feeds per tooth while simultaneously reducing the radius corrections. For unfavourable conditions, Walter offers the thread milling inserts with a D61 geometry that provides an “anti-vibration land”.

Horn offers the geometry for a variety of systems for external and internal grooving. (Source: Horn/ Sauermann)

Lisker said coolant-through technology is especially helpful when cutting nickel-base alloys like Inconel that transfer heat back to the tooling. Besides maintaining thermal stability on the cutting edge, he said coolant-through systems disperse chips to help with chip control.

Workpiece is held in a chuck, mounted on a face plate or secured between centers and rotated while a cutting tool, normally a single-point tool, is fed into it along its periphery or across its end or face. Takes the form of straight turning (cutting along the periphery of the workpiece); taper turning (creating a taper); step turning (turning different-size diameters on the same work); chamfering (beveling an edge or shoulder); facing (cutting on an end); turning threads (usually external but can be internal); roughing (high-volume metal removal); and finishing (final light cuts). Performed on lathes, turning centers, chucking machines, automatic screw machines and similar machines.

Covis uses a variety of tools from Big Kaiser, including boring heads, roughing heads and the modular vibration dampening system Smart Damper. The Smart Damper bars have enabled deep boring with high precision finishes on valves with Inconel, with substantially better results than were possible using solutions from other suppliers. All the machining centres in the workshop are also equipped with the Big-Plus spindle system, the only system in the world to guarantee double simultaneous cone-flange contact between the spindle and the machine. This is another important step that gives more rigidity to the machine and keeps vibrations under control.

Shops can get off to a good start with grooving by making sure the tool in the lathe turret is perpendicular to the workpiece surface.

When a grooving operation is required, don’t plunge in without giving careful thought to what you’ll be using and how to go about the task. Specific items that should be considered include proper preparation, tool and process options and what the latest technology has to offer. Time spent upfront on these important topics can pay off in longer tool life, faster cycle times and better grooving results.

Fluid that reduces temperature buildup at the tool/workpiece interface during machining. Normally takes the form of a liquid such as soluble or chemical mixtures (semisynthetic, synthetic) but can be pressurized air or other gas. Because of water’s ability to absorb great quantities of heat, it is widely used as a coolant and vehicle for various cutting compounds, with the water-to-compound ratio varying with the machining task. See cutting fluid; semisynthetic cutting fluid; soluble-oil cutting fluid; synthetic cutting fluid.

The ST-Cut series features a unique insert replacement system that provides fast and easy changeovers of inserts from both sides of the tool. This is particularly suitable for manufacturers running sliding head turning centres where space is often limited inside the working envelope. Also, the innovative clamping system demonstrates high repeatability and excellent rigidity for manufacturers aiming to part-off components with a maximum part-off diameter of 17 mm. The ST-Cut Series encompasses everything from parting-off, groove-turn, square grooving, round grooving, threading, front and back-turning as well as face grooving. From the parting off-line, the ST-Cuts series incorporates both left and right-hand inserts with a cutting width from 0.5 to 2 mm with a range of cutting depths, geometries and insert grades. Similarly, the square grooving/turn and round grooving line offers left and right-hand variants with insert widths from 0.5 to 3 mm with the round groove inserts offering a choice of radii from 0.2, 0.5, 0.75, 1, 1.25 and 1.5 mm. From a threading perspective, the left and right-hand inserts are supplied with a 55 ° and 60 ° profile option with a maximum insert width of up to 3.2 mm.

In some instances, he said, “a coated tool is only a few dollars more than an uncoated one. But in the right materials, it can give you three to five times the tool life of an uncoated tool. So you get a great return for a small investment in the tool.”

East said one reason to opt for a groove/turn operation is that chip control is easier when turning than when plunging. In addition, he said groove/turn processes reduce cycle time because metal removal rates are usually “a lot better” than those achieved with plunging.

Machining operation in which material is removed from the workpiece by a powered abrasive wheel, stone, belt, paste, sheet, compound, slurry, etc. Takes various forms: surface grinding (creates flat and/or squared surfaces); cylindrical grinding (for external cylindrical and tapered shapes, fillets, undercuts, etc.); centerless grinding; chamfering; thread and form grinding; tool and cutter grinding; offhand grinding; lapping and polishing (grinding with extremely fine grits to create ultrasmooth surfaces); honing; and disc grinding.

If the tool isn’t, “the edge of your tool is going to be tilted, so you could potentially be running scrap parts,” said Clay East, national product manager for grip systems at Iscar Metals Inc. in Arlington, Texas.

Machining grooves and shallow channels. Example: grooving ball-bearing raceways. Typically performed by tools that are capable of light cuts at high feed rates. Imparts high-quality finish.

Substances having metallic properties and being composed of two or more chemical elements of which at least one is a metal.

The ST-Cut series from Vargus presents a solution for small part turning applications. (Source: Vargus)

He recommends running an indicator along the length of the tool to check perpendicularity. For a 102 mm (4") tool length, the measurement should be off by no more than about 0.1 mm (0.004"), he said.

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The smooth cutting action and low deflection of the T2710 milling cutter is created by both the easy-cutting geometry and the variable internal coolant supply. (Source: Walter)

The Schunk Rota THW3 chuck with quick-change jaws and patented sealing ensures consistent clamping forces, long maintenance intervals and high reliability. (Source: Schunk)

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Productivity is also in the centre of Open Mind’s CAM solution. Bavarian contract manufacturer BAM is going all in with digital processes in an effort to further reduce costs and project times in contract manufacturing. With the support of Open Mind, the company has used Hypermill Automation Center to streamline and markedly speed up CAM programming.

The chuck's base body is hardened and extremely rigid, and even in case of heavy-duty machining precise and reliable machining results can be achieved. Due to the optimized outside contour, the chuck is perfectly designed for milling tasks. Versatile use of the chuck is ensured: it has a large through-hole of 52 mm (size 200) up to 165 mm (size 630), center sleeves that can be exchanged from the front, and the option of I.D. and O.D. clamping. Furthermore, the power lathe chuck can also be complemented with an adjustable workpiece stop. Searching for the matching chuck jaws for the Schunk Rota THW3 is simplified by the jaw quickfinder: It takes just four clicks to get to chuck manufacturer, chuck type, chuck size and product details. The user receives a list of all machtching chuck jaws from over 1200 jaw types of the world's largest standard chuck jaw program from the manufacturer. The matching chuck jaws can be directly selected within the quickfinder and ordered in the online shop.

When highly demanding projects must comply with very tight tolerances on unique components manufactured from hard-to-machine materials such as Inconel, a tool needs industry-leading reliability. High-precision tooling products have enabled the Italian technical-sales company Covis to meet the tough requirements of its customers. Founded in 1994, Covis designs and produces tailor-made solutions to strict deadlines and quality standards, managing and certifying the entire production cycle at its three operating sites in Italy. The company specializes in precision mechanical machining and welding, including machining of exotic and treated materials such as steel, Inconel, Duplex and Super Duplex and other special alloys.

The design of the Smart Damper heads shortens the distance from the damping mechanism to the cutting edge. (Source: Big Kaiser)

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East said groove/turn operations used to require two things. One was that CAD/CAM companies had to be pressed to create code for the work. Also, he said a special type of insert was needed, one with a chipformer on the front for plunging, plus a chipformer on each side for turning.

William Leventon is a contributing editor to Cutting Tool Engineering magazine. Contact him by phone at 609-920-3335 or via email at wleventon@gmail.com.

France also recorded a very negative development. Here, the effects of the pandemic were even more drastic, with declines of 35 % in the French market for cutting tools and as much as 50 % for clamping devices, summarizes Horn. In Spain, the downturn was also rather severe. The Spanish market is heavily dependent on the automotive industry whose production was also restricted. Here, the recovery has now begun, albeit still somewhat subdued.

Another is the variety of coolant-through tooling options available. As the name suggests, this type of tooling features internal passages for coolant flow. White said many different toolholders feature coolant-through designs that get coolant right to the cutting edge to lessen thermal degradation of the substrate.

Another timesaving option he recommends is using a multigroove tool to cut multiple grooves right next to each other. To simultaneously cut four adjacent grooves, for example, shops can use an insert with four adjacent cutting edges.

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Provided with a part drawing or the part itself, Mikron will grind a tool designed for the special form or profile to be grooved into the part.

When customers ask why they should pay more for Jet-Cut holders, he points out that coolant pinpointed on the cutting edge increases tool life, which translates into more parts per edge. He notes as well that efficiently delivered coolant quenches chips and makes them brittle, so they break up more easily.

In the following article we are presenting some of the new solutions developed by toolmakers in the recent past. Delivering on precision, efficiency and productivity are a common goal all of them have in common.

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If chamfers are on the top of the grooves, Coomer said the insert can be modified to create those features as well, “so you can cut all four grooves and put chamfers on them in one shot.”

Grooving also goes better these days thanks to advances in tool coatings. The latest coating materials are heat- and wear-resistant, which increases tool life. White said they additionally improve speeds and feeds by preventing workpiece materials from sticking to tools.

The design of the Smart Damper heads shortens the distance from the damping mechanism to the cutting edge, i.e. the source of vibration. This significantly improves vibration damping performance at the tool assembly, minimizing chatter and vibration, thus making it ideal for critical applications requiring very long tools, for example in the automotive, energy and aerospace industries. The modular CK/CKB system is compatible with most major spindle interfaces and enables versatility in tooling combination lengths up to a maximum of ten times diameter. All tools have a coolant-through design and offer three different insert holder options per head size.

“If you can’t get the chips out of the bore,” White said, “usually you will re-cut them, and then they will scar the surface.”

At BAM, CAM programming represents the final digital step in the transition from the customer design to the finished workpiece. Automation has helped reduce CAM programming times in Hypermill by 70 to 80 %. Thanks to the powerful 2.5D, 3D and 5 axis cycles of the solution, the contract manufacturer has succeeded in reducing setup and programming times at the machining centers, resulting in increased efficiency and higher capacity utilization. Stefan Bauer, Head of Manufacturing at BAM explains that with its feature technology, macro databases and associated process, Hypermill would also provide a solid basis to automate programming and significantly reduce time expenditure by reusing pre-existing programming know-how. The automation center is built on feature and macro technology, allowing any user to standardize machining steps and automatically apply them to new workpieces. Open Mind honed and optimized the process for use at BAM. To handle a wide variety of orders and workpieces, the CAD/CAM manufacturer integrated an interactive user guide which uses a few parameters to control automated programming. For Marco Bauer, Managing Director of BAM, one of the key factors for us was that Open Mind develops their software in-house. As a result, the customer was able to obtain customized functions for their automation projects very rapidly, which — according to Bauer — has helped the company improve leaps and bounds.

“Even if the groove was wider than it was deep,” he said, “if it had 90-degree corners, you would take a groove tool and plunge all of that material out. Today, we want to apply a groove/turn solution in these cases.”

If the chipbreaker doesn’t, Coomer said, “the chips will get stuck, especially once you get down into the groove a little bit. This will cause some marring of the parts.”

He advises those who use inserts to cut grooves to make sure the chipbreaker folds the chip in a way that makes it smaller than the groove being cut.

“When customers come to us for grooving tools, it is usually for a turnkey operation” — that is, a job for which Mikron produces most if not all of the different tools needed to make a part, said Sales Manager Nathan Lisker.

The system available from ITC communicates with the cloud-based Supply Pro Intelligent Software solution that can be configured to meet your business demands. Working with the supplier and their technical partners at Tooling Intelligence, end users can choose from a range of options to optimise their vending software by adding a VIM (Virtual Inventory Module). This allows inventory to controlled away from the vending machine. These could include fixtures, oils, and basically anything that cannot be stored in the vending machine. A barcode reader can be added to the system, so anything vended can be allocated to a works order. This gives an accurate tooling cost for each works order. A major bonus when quantifying costs of tooling in a production environment. As a fully reconfigurable system, the Smart Drawer can be adapted over time as the inventory requirements of your business evolve with the facility for auxiliary units to be added to increase the storage capacity.

If operators want to manufacture turned parts more efficiently, low-maintenance and fail-safe precision clamping devices are required. These can be quickly and easily converted, and, if necessary, can also be used for automatic loading. The Schunk Rota THW3 jaw quick-change chuck and patented sealing of the chuck mechanism has been designed with this in mind. Equipped with a jaw quick-change system, the Rota THW3 can be quickly converted for a new range of parts on CNC lathes, pick-up lathes and turn/mill centers, and has an excellent jaw repeat accuracy of up to < 0.02 mm. This means that previously turned out sets of jaws can be repeatedly used, even for applications where the tolerances are challenging. The jaw stroke of the straight-serrated base jaws amounts to 6.7 mm to 10.5 mm — depending on the jaw size. A ring piston transmits the force directly and therefore ensures a high degree of efficiency: The clamping force of the smallest size, the Rota THW3 200 is 64 kN; and as of size 400, the chuck achieves a clamping force of 240 kN.

Substance used for grinding, honing, lapping, superfinishing and polishing. Examples include garnet, emery, corundum, silicon carbide, cubic boron nitride and diamond in various grit sizes.

No matter what applications the cutting tools are needed to, it's always important to have them readily at hand and neatly organized. To this end, the manufacturer and supplier of solid carbide and indexable cutting tools, Industrial Tooling Corporation (ITC), has introduced the new Smart Drawer vending solution.

“If (the tool) is going on a lathe, our message is to use coolant-through tooling as a first choice,” said East, whose company offers tooling products of this type called Jet-Cut.

Walter also focusses on productivity by extending their concept of their multiple-row thread milling cutters for producing shorter threads. Thanks to small spaces between insert rows, the T2710 has been specially designed for highly productive processing of thread depths up to 1.5 x D, the company says. It adds that even with short thread depths, the simultaneous machining of several thread sections by the new T2710 Series reduces machining time. Productivity is further amplified by the highly wear-resistant thread milling inserts of the Walter WSM37S Tiger-tec Silver grade.

“These can be challenging if they are at the bottom of a small-diameter hole,” he said. “You’ve got to have the proper reach to get to the groove (location) and then be able to machine it successfully.”

Turning machine capable of sawing, milling, grinding, gear-cutting, drilling, reaming, boring, threading, facing, chamfering, grooving, knurling, spinning, parting, necking, taper-cutting, and cam- and eccentric-cutting, as well as step- and straight-turning. Comes in a variety of forms, ranging from manual to semiautomatic to fully automatic, with major types being engine lathes, turning and contouring lathes, turret lathes and numerical-control lathes. The engine lathe consists of a headstock and spindle, tailstock, bed, carriage (complete with apron) and cross slides. Features include gear- (speed) and feed-selector levers, toolpost, compound rest, lead screw and reversing lead screw, threading dial and rapid-traverse lever. Special lathe types include through-the-spindle, camshaft and crankshaft, brake drum and rotor, spinning and gun-barrel machines. Toolroom and bench lathes are used for precision work; the former for tool-and-die work and similar tasks, the latter for small workpieces (instruments, watches), normally without a power feed. Models are typically designated according to their “swing,” or the largest-diameter workpiece that can be rotated; bed length, or the distance between centers; and horsepower generated. See turning machine.

Common grooving options today include solid-carbide tools and indexables. When it comes to grooving, the focus at Scientific Cutting Tools Inc. in Simi Valley, California, is mainly on grinding solid-carbide tools for cutting internal grooves for things like threads and O-rings, said Sales Director Todd White.

Coolant Ring Technology holders allow better coolant penetration into a bore during cutting operations. Image courtesy of Scientific Cutting Tools

Vargus has introduced its new ST-Cut line of cutting tools for small part machining. Developed specifically for the turning of small components on Swiss-type sliding head-turning machines, the ST-Cut line presents a solution for virtually every small part turning application.

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Mapal is launching a new, particularly economical system of replaceable head reamers — the Press-to-Size-Reamer (PSR) — for customers who manufacture in large series. The new development reduces the costs per bore massively, the company claims. The solid carbide replaceable heads of the new reaming programme launched by Mapal are specifically adapted to individual diameters and geometries. The replaceable head system for the diameter range 10 to 25 mm consists of a robust holder, the solid carbide replaceable head and a coolant distribution element. The connection is highly accurate. This means that the heads can be changed by the customer’s employee on site without any adjustment or logistics effort, a big plus in terms of cost-effectiveness. The replaceable head is merely exchanged and disposed of. There is no provision for reconditioning the replaceable heads. By eliminating the logistics cycle, the new replaceable head system significantly improves the economic efficiency of reaming operations in large-scale production. This effect is even reinforced by the fact that, in contrast to carbide-tipped reaming tools, the solid carbide replaceable heads can be designed with a CVD coating — with correspondingly positive effects on tool life.

In a recent statement, Ecta President Markus Horn highlighted the importance of European cutting tool manufacturers on the common market. 60 % of cutting tool exports from the 27 EU member states do not leave Europe, Horn pointed out. Another 13 % of total deliveries go to the other European countries. This means that Europe is the sales market for almost three quarters of our European tools. After Brexit, exports to the UK also declined by 28 %, while the deliveries from the UK fell even more sharply, by 29 %. Italy also reported very sharp declines in orders — of around a quarter in the first nine months of 2020 — due to the imposed company closures. But at the end of the year, production in the automotive industry in Italy picked up again strongly, giving cause for hope.

When indexable tools are used for grooving, “many times your chipbreaker is a big key to success,” said Travis Coomer, national key account manager at GWS Tool Group in Tavares, Florida.

A single insert also can be used to combine grooving and turning processes. This wasn’t the case back when East worked at a machine shop.

When a groove is very wide, White warns that cutting it all at one time can put too much pressure on the tool, causing deflection problems and even breakage. So in cases like this, he believes that a better approach can be to employ a peck cycle — in other words, making a couple of passes to depth using a tool that’s thinner than the groove, then moving the tool over a little and doing the same again. Besides going easier on the tool, he said a peck cycle gives a chance to flush out potentially problematic chips.

The solution supports inventory management and helps to cut costs on the shop floor. Using smart technology to dispense single or multiple items, the configurable drawer system ensures that important tools are always available. The Smart Drawer makes secure storage and dispensing simple and delivers reliable, accurate and monitored control of cutting tool inventory. The system comprises individually locked compartments that are controlled by an easy-to-use touchscreen interface and operation is fully customisable to provide staff with self-serve access to cutting tools and equipment on demand. With a high storage capacity and a small footprint, the Smart Drawer makes storing, tracking and dispensing products quick and easy, without compromising reliability.

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The inserts are available in two grades, this includes the Altin PVD coated VPG grade for achieving medium to high cutting speeds on alloy steel, stainless and titanium alloys. Alongside this, the uncoated VS020 sub-micro grade is recommended for medium to low cutting speeds. The VS020 is uncoated to ensure a sharper cutting edge that is crucial for very small components where accuracy is paramount. To cater for the diverse demands of small part turning companies, Vargus has introduced the ST-Cut Series with a choice of tool holders that include square shank tool holders, step square shank tool holders and square shanks with 90 ° tools. The square shank tools are available in both left and right-hand variants with an adjusting screw, key and torque limiting adapter. The tool shanks that accommodate the various insert geometries are available as an 8 by 10 mm variant as well as a 10, 12, 16 and 20 mm square shank with an overall length of either 110 mm or 120 mm. Alongside the square shank, tools are the stepped square shank tool holders. Also available in 8 by 10 mm, 10, 12 and 16 mm square shanks, the stepped tool holders offer a step of 30 or 40 mm to provide the end-user with additional reach when cutting features in intricate parts or attaining access to difficult to reach areas. Completing the line-up of tool holders is the square shank 90 ° right-hand tool body. Vargus provides the 90 ° tool body with the option of a 10 mm or 12 mm square shank that is 110 and 120 mm long for the respective tool widths. As well as the ST-Cut Series, Vargus UK can also offer its VG-Cut series of parting off solutions with chip formers and high-pressure coolant, its Microscope range for small boring applications and the Groovical series for precision grooving.

For deep grooving applications, the company typically produces solid-carbide tools because of their superior rigidity. White pointed out that the allowable length-to-diameter ratio for carbide tools is 10-1 compared with 3-1 for indexable toolholders made of steel.

Chip problems like these can be prevented by improved coolant delivery, which is possible today thanks to several developments. One is the increased coolant pressures produced by current machines. White said these pressures typically range from 300 psi all the way up to 1,000 psi.

Many part designs include a chamfer at the top of the groove to eliminate burrs. In these cases, shops can opt for grooving inserts that incorporate chamfering, said Coomer, whose company makes such inserts. By cutting the groove and chamfer at the same time, users eliminate a secondary operation to create the chamfer when the groove is finished.

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If the groove to be cut isn’t too deep, he believes that Top Notch-style inserts may be a good choice. These feature molded notches on the top and bottom that seat the inserts in their holders. With the inserts held at a 3-degree angle, the notches pull them back into the pocket during cutting, he explained, making the system very rigid and stable.

Precision tools are a speciality of the European market. Their quality allows manufacturers around the world to produce high-technology parts and components for sophisticated applications. The innovative spirit of the industry is the trump card for the emerging recovery after the Corona crisis. We present some of the highlights recently launched by international toolmakers.