Another example: “Heli Grip is a game changer due to its unique twisted geometry, enabling depths of cuts to go beyond the second edge of the insert without damaging it.” He said that results in “much deeper depths of cut—grooving and excellent groove turn capabilities.”

Industry changes also create other considerations for toolmakers and their customers. “Geometry always plays a critical role in grooving operations,” Walter’s Garud said. “But parting-off operations typically tend to need the inserts to go all the way to the center of the bar, so cutting speeds are zero at the center, which means tougher grades are always going to be better than the harder grades. Also, chip-crimping is quite important. Not only do the chips need to curl into ‘sixes and nines’ shapes, they also need to be folded axially, so the chip breakers need to be aggressive to fold the chips.”

Some trends in machining remain constant. Machine speeds continue to increase. Difficult-to-cut materials are used more frequently. The desire for better cooling, chip control and reliability remains.

Added Steve Vanderink, national product specialist for grip products at Iscar USA, Arlington, Texas, “Users are demanding ease of indexing of the insert with accurate repeatability while increasing productivity with rigid support and strength in the pockets—all while keeping an eye on the economics. The market wants it all. Innovation is the driving force for solutions to the market’s needs.”

Cylindrical milling in GibbsCAM 2023 is easier with direct selection of a ‘Slice’ in the CS depth axis -- select a closed profile to machine a cylindrical boss or pocket, or select two loops to machine a groove or ring without the need to extract edge geometry and unwrap the shape. New Spiral Boring functionality cuts a spiral out to the full diameter at each Z step, which substantially increases cutting feed rate and depth due to a more consistent tool load. In addition, Mill Roughing can now omit cavity areas to support high-speed mill tools that cannot plunge or ramp.

Cambrio, a leading CAD/CAM innovator in the production machining industry has announced the new release GibbsCAM 2023. New developments continue the focus on core capability, while introducing new technology in collaboration with Sandvik Coromant. GibbsCAM 2023 features a number of significant Turning enhancements including the highly effective implementation of Sandvik Coromant’s PrimeTurning strategies. These new cutting methodologies permit turning and facing in all directions, delivering dramatic increases in high volume production. PrimeTurning has proven to deliver cycle time reductions of up to 50%, and more than 500% increase for insert tool life. PrimeTurning uses the slope of the insert for chip thinning to allow you to make heavy cuts and spread cutting forces and heat over a larger portion of the cutting edge, which in turn contributes to longer tool life. In addition, PrimeTurning adapts the feedrate (excellent for cutting on a taper) to constantly manage chip thickness which is ideal for high-volume and unattended environments. PrimeTurning supports two new tool types (CoroTurn Prime Type-A with three 35° corners for finishing and fine roughing/getting into grooves etc, and CoroTurn Prime Type-B with two strong corners for bulk roughing/heavy cutting) that both utilize a low lead angle to improve surface finish. Commenting on the latest development, Åke Nilsson, Global Product application manager for Turning tools at Sandvik Coromant said: “We have now extensively tested the PrimeTurning cycle in GibbsCAM, and it's really good. The team have taken an innovative approach and I must say that they've made a tremendous job with the technology implementation.” Other enhancements include a new option in most Turning processes to control Cutting Load Variation in order to suppress resonance-induced chatter and improve chip breaking for CNC machines. This machine capability is also called variable spindle speed by Okuma, and low frequency vibration by Citizen. VoluTurn functionality has also been extended to manage the active control of chip thickness during the cut by varying the feed rate instantaneously with any changes in cut depth. Thread Turning operations have been expanded with Face Threading, Variable Pitch Threading, Multi-pitch, and Position Tool Front options. Users can produce a spiral thread on the face of a part, vary pitch threads incrementally per revolution, or generate different pitches on a continuous thread, with easy control of exact start/end specs in the tool dialog. Alongside many other Turning enhancements, it is now possible to specify Rake and Back Relief for tool inserts to more accurately define the 3D geometry of the tool inserts to provide a tool representation that perfectly matches what the customer is experiencing. Also, the Elliptical Contour process may now be used for elliptical bores inside of solid parts, and supports a radial (Xr) stock offset, for both inner diameter (ID) and outer diameter (OD) machining. Cylindrical milling in GibbsCAM 2023 is easier with direct selection of a ‘Slice’ in the CS depth axis -- select a closed profile to machine a cylindrical boss or pocket, or select two loops to machine a groove or ring without the need to extract edge geometry and unwrap the shape. New Spiral Boring functionality cuts a spiral out to the full diameter at each Z step, which substantially increases cutting feed rate and depth due to a more consistent tool load. In addition, Mill Roughing can now omit cavity areas to support high-speed mill tools that cannot plunge or ramp. GibbsCAM 2023 extends the default drill cycle types to include five more: gun drilling, variable peck (full out and chip breaker), and peck tap (full out and chip breaker). In addition, a new Multifunction Insert Drill type is supported which can be used to perform both turning and drilling/boring operations (such as the Sandvik Coromant CoroDrill 880 series). The Multifunction Insert Drill tool type can seamlessly switch between turning, lathe drilling, and mill drilling without retraction or tool change motions. Also included is a new option for Lathe Drilling with counter-rotating tools that instructs the live tooling spindle to turn in the opposite direction at a specified RPM to effectively increase spindle speed and significantly boost material removal rates. A number of new features for machine support include the ability to set tool changes from alternate origins. This now includes the ability to set the tool change home location based on Part (as in previous versions), Part Station, Machine, or Tool Group. In addition, it is also possible to flag tool motions with abnormally high feedrates and provide a safety warning to the operator. Alongside new simulation modes such as Fixture Visibility, GibbsCAM 2023 significantly boosts its simulation feature set. Lastly, organising parts is easier than ever to match the way you work. GibbsCAM 2023 lets you categorise and organize workgroups and coordinate systems within a part, and specify active and inactive operations which significantly helps users to part information throughout the CAM workflow, especially with large complex machining processes. To improve ease of use, new tabs have been added to allow the setting of work areas limits on a part-by-part basis and assign to new toolpath operations. In addition, the Work Fixtures tab within the Post Processor dialog can now group offsets in use by operation coordinate system. This increases visibility and program safety when multiple coordinate systems are used on a single fixture offset. www.cambrio.com

Improvements in machine tools have also altered the way companies design tools. “The biggest improvement in machines that I have noticed is more machines are running high-pressure coolant,” Kollenbroich of Horn said. “Even the standard offering from most manufacturers is a considerable jump in pressure from what it was just a few years ago. High-pressure coolant offers benefits in chip breaking. Coolant-through tools, with better and more focused coolant delivery, remove chips from the work zone. This helps improve tool life and overall performance.”

“As tool designers, we need to increase the pocket security of our grooving platforms to allow customers the freedom (to) turn in all directions,” said John Winter, turning specialist at Sandvik Coromant, Fair Lawn, N.J.

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Thread Turning operations have been expanded with Face Threading, Variable Pitch Threading, Multi-pitch, and Position Tool Front options. Users can produce a spiral thread on the face of a part, vary pitch threads incrementally per revolution, or generate different pitches on a continuous thread, with easy control of exact start/end specs in the tool dialog.

Kollenbroich of Horn noted that managing centerline is critical. “Centerline can be your biggest friend and your worst enemy. All manufacturers design their tools to work on center. When a machine is off, even slightly, things become unpredictable. Customers typically experience a drop in tool life, maybe poor surface finish or, worse yet, catastrophic failure. It is critical to apply part-off and grooving tools properly, and on center.”

Commenting on the latest development, Åke Nilsson, Global Product application manager for Turning tools at Sandvik Coromant said: “We have now extensively tested the PrimeTurning cycle in GibbsCAM, and it's really good. The team have taken an innovative approach and I must say that they've made a tremendous job with the technology implementation.”

At Horn USA, the company is offering coolant on more of its products. “This includes part-off and grooving holders and even some inserts,” Kollenbroich said. “Getting coolant to the cutting edge has many advantages. For one, having a more accurate delivery method for the coolant direction helps in cooling the work zone. It also offers the benefit of chip breaking when used with higher pressure applications.”

“Also, lower vibrations lead to less pitting of the tool pocket, increasing toolholder life,” Garud continued. “The new patented design by Walter for our DX18 inserts securely clamps the inserts on three sides.” It also has “a secure prismatic base: a V-shaped top groove for the top clamping finger and a small double-faceted groove at the back of the insert to seat it securely in the insert pocket.”

Other enhancements include a new option in most Turning processes to control Cutting Load Variation in order to suppress resonance-induced chatter and improve chip breaking for CNC machines. This machine capability is also called variable spindle speed by Okuma, and low frequency vibration by Citizen. VoluTurn functionality has also been extended to manage the active control of chip thickness during the cut by varying the feed rate instantaneously with any changes in cut depth.

Higher machine speeds are also a big part of the demand on tools. “As the machines get more capable of higher speeds and torques, and the demand to get more out of the same tool constantly increases, manufacturers have to respond accordingly,” said Sarang Garud, product manager at Walter USA LLC, Waukesha, Wis.

One question is what to expect in the next few years. “I believe one thing we will see is machines equipped with sensor monitoring technology watching slight changes in the tool and adjusting accordingly,” Kollenbroich said. “Some machine manufacturers already have things like this, but they are not accurate or sensitive enough yet. Incorporating this sensor technology into the toolholder and tying directly into the machine control is a possibility.”

Said Winter of Sandvik Coromant, “We will see machines turning in all directions and the requirement for part-off and grooving tools is to do the same.”

Advancements in carbide substrates are “ever changing and we are seeing new grades and coatings that are making a meaningful impact in tool life,” he added. “Industry 4.0 is expanding into tooling more and more. Tracking of tool life and wear is becoming a seamless part of the manufacturing process.”

Added Vanderink of Iscar, “Technically, center-height position of the tool is critical. The process of a square tool plunging into a round part is very abusive. The centerline dynamic is not fiction. It is real and essential for success in these applications.”

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Alongside many other Turning enhancements, it is now possible to specify Rake and Back Relief for tool inserts to more accurately define the 3D geometry of the tool inserts to provide a tool representation that perfectly matches what the customer is experiencing. Also, the Elliptical Contour process may now be used for elliptical bores inside of solid parts, and supports a radial (Xr) stock offset, for both inner diameter (ID) and outer diameter (OD) machining.

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These new cutting methodologies permit turning and facing in all directions, delivering dramatic increases in high volume production. PrimeTurning has proven to deliver cycle time reductions of up to 50%, and more than 500% increase for insert tool life. PrimeTurning uses the slope of the insert for chip thinning to allow you to make heavy cuts and spread cutting forces and heat over a larger portion of the cutting edge, which in turn contributes to longer tool life.

“Multi-axis, multi-spindle machine tools with Y-axis capabilities are emerging to complete parts in one setup,” Vanderink continued. “The use of robots on the shop floor is increasing and is becoming a viable operation for small to medium-sized shops now.”

“We are seeing the increased usage of Y-axis grooving and parting-off. By using this axis of the machine, we are able to increase cutting data, allowing our customers to reduce their cycle times,” he said. “Machine tool builders are adding features to their machines that allow for the use of the Y axis. Also, builders are looking at increasing the stroke of the Y axis, allowing for increased diameters where you can use Y-axis part-off tools.”

The company also looks to coating for product improvement. “We offer coatings that are capable of handling heat better, which in part-off and grooving is always a challenge,” he said.

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New developments continue the focus on core capability, while introducing new technology in collaboration with Sandvik Coromant. GibbsCAM 2023 features a number of significant Turning enhancements including the highly effective implementation of Sandvik Coromant’s PrimeTurning strategies.

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In addition, PrimeTurning adapts the feedrate (excellent for cutting on a taper) to constantly manage chip thickness which is ideal for high-volume and unattended environments. PrimeTurning supports two new tool types (CoroTurn Prime Type-A with three 35° corners for finishing and fine roughing/getting into grooves etc, and CoroTurn Prime Type-B with two strong corners for bulk roughing/heavy cutting) that both utilize a low lead angle to improve surface finish.

Horn also offers a Y-axis part-off system. “This system uses the Y axis of certain lathes as feed direction,” Kollenbroich said. “This switch in axis feed directs forces back into the holder instead of against the holder. The improved strength allows for feed rate increases of two or three times that of standard X-axis part-off applications.”

GibbsCAM 2023 extends the default drill cycle types to include five more: gun drilling, variable peck (full out and chip breaker), and peck tap (full out and chip breaker). In addition, a new Multifunction Insert Drill type is supported which can be used to perform both turning and drilling/boring operations (such as the Sandvik Coromant CoroDrill 880 series). The Multifunction Insert Drill tool type can seamlessly switch between turning, lathe drilling, and mill drilling without retraction or tool change motions. Also included is a new option for Lathe Drilling with counter-rotating tools that instructs the live tooling spindle to turn in the opposite direction at a specified RPM to effectively increase spindle speed and significantly boost material removal rates.

“The side-lock, or ‘smart lock’ as the technology is called, allows the users to index the inserts while the tool is still clamped onto the gang tooling of a Swiss machine,” he continued. “The side access to the indexing screws allows a time reduction of up to 70 percent in insert indexing, saving valuable time on high-volume Swiss machining operations.”

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Lastly, organising parts is easier than ever to match the way you work. GibbsCAM 2023 lets you categorise and organize workgroups and coordinate systems within a part, and specify active and inactive operations which significantly helps users to part information throughout the CAM workflow, especially with large complex machining processes. To improve ease of use, new tabs have been added to allow the setting of work areas limits on a part-by-part basis and assign to new toolpath operations. In addition, the Work Fixtures tab within the Post Processor dialog can now group offsets in use by operation coordinate system. This increases visibility and program safety when multiple coordinate systems are used on a single fixture offset.

Sandvik Coromant works to make its products flexible. Winter said that with CoroCut 1-2 “you can part-off, groove, face groove and do high-feed machining of hardened steel. The CoroCut QD platform can part-off in both the X and Y axis and face groove.”

A number of new features for machine support include the ability to set tool changes from alternate origins. This now includes the ability to set the tool change home location based on Part (as in previous versions), Part Station, Machine, or Tool Group. In addition, it is also possible to flag tool motions with abnormally high feedrates and provide a safety warning to the operator. Alongside new simulation modes such as Fixture Visibility, GibbsCAM 2023 significantly boosts its simulation feature set.

Progress in various manufacturing technologies may play a role in the future for parting and grooving, Iscar’s Vanderink said. “Additive manufacturing will be a big player from here on out,” he said. “Already, new concepts are on the way due to this technology. Additive manufacturing producing near-net shaped parts will change how removing material is viewed. This concept alone will drive the innovation needed to accommodate these types of components.”

“Users are always demanding the same thing,” said John Kollenbroich, head of product management at Horn USA Inc., Franklin, Tenn. “More tool life and predictability, better chip control and surface finish. These demands have not changed in many years, nor will they change anytime soon.”

“Jet cut tooling is vital today,” he said. “Iscar has taken great care in making sure coolant is introduced to the cutting edge of the insert even when high pressure is not accessible. Data has shown that in all cases this makes a difference in tool life and part quality.

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Iscar has had a series of product launches to address customer demands. “Cut Grip is one of the most complete and comprehensive grooving lines on the market,” Vanderink said. “Iscar promotes and champions the GTO (groove turn operation) as a cornerstone process for this line. Straight grooving and then turning side to side utilizing all edges of the insert reduces cycle time while producing excellent part finishes.”

According to Garud, Walter is also adjusting design. “The need for higher volumes and reduced cycle times is always weighing down on tool manufacturers,” he said. “Walter recently introduced a new line of G4014 toolholders specifically designed for gang tooling. One of the key features of these holders is the side-access screw to clamp the insert into the toolholder.

He also said clamping is an issue. “Using torque wrenches when clamping inserts in all parting and grooving tools is essential to maintain clamping force, tool integrity and finally part quality.”

Kollenbroich described how Horn addressed that challenge with its 960 part-off system. “This is a cassette-based, coolant-through design that offers a major upgrade in blade stability,” he said. “This additional stability results in great improvement in tool life. Customers can realize gains of double or triple the tool life while showing dimensional improvements in flatness and surface finish.”

Walter USA has adjusted the way it clamps its inserts. “Usually the grooving inserts are held either through a self-clamping mechanism or through a ‘top-clamp’ screw-down mechanism,” Garud said. “The more secure the insert in the pocket, the lesser the tendency of vibration and longer the insert life.