Optimization of machining parameters for turning operation of heat-treated

 2024-06-17 09:52:52

Ti-6Al-3Mo-2Nb-2Sn-2Zr-1.5Cr alloy by Taguchi method - milling feeds and speeds table

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.

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.

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

The deburring process time stressed Paramount’s ability to meet its delivery dates with the client, and, worse, the difficulty of successfully deburring these cross-drilled parts led to rejections from the customer due to remaining burrs or uneven deburring. While Paramount did improve its process over the first job runs, the shop wanted to improve its process.

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.

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

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

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.

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.

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.

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

Because of the high material removal rate creep-feed grinding can deliver in challenging materials, grinding might not be just the last step in the process—it might be the process.

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

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

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

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.

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

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

With J.W. Done’s recommended Orbitool strategies in hand, Rivas created a tool path routine. He used a 40x magnification scope to make minor tweaks and adjustments in the tool path until the initial production process yielded significant reductions in burrs. He took the parts to Martin Loera, the shop’s deburring expert, who agreed that use of the Orbitool and Rivas’ tool path would simplify deburring. Instead of conducting full deburring as a secondary process, Loera would only need to confirm the edge breaks and address a small amount of external deburring.

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

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

The Orbitool from J.W. Done helped Paramount Machine eliminate a secondary deburring process, saving 75 process hours across a 2000-part run and enabling the shop to meet its profit and delivery time goals.

Once the tool reaches the intersection between the holes, the disk falls away from the wall, giving the cutter access to the burr. As the disk traces the contour of the cross-hole intersection, the cutter only affects the burred areas. Paramount adds that the flexible shaft enables the deburring tool to remain in contact with irregular shaped features.

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

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.

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.

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

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

In a twist of irony, Paramount Machine machinists Eric Van Orden and Luis Rivas found an advertisement for J.W. Done’s Orbitool in Modern Machine Shop. The pair researched Orbitool and decided to reach out to J.W. Done. After explaining that the part Paramount was producing had four cross-holes with 0.120-inch diameters intersecting a through-hole with a 0.125-inch diameter in L605 cobalt nickel alloy at a 0.0004-inch total tolerance, Orbitool made a tooling recommendation: the P/N 14000D Orbitool 3/32 Double Hemisphere Cutter and the P/N 14000 Orbitool 3/32 Single Hemisphere Cutter.

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

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

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

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.

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.

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

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).

Paramount Machine, a job shop in Salt Lake City, Utah, is familiar with this dilemma. During one job with 2000 parts that featured cross-drilled holes for a commercial aerospace application their they found that producing the parts required 185 hours of machine time, with an additional 120 hours in the foreign object debris (FOD) room to deburr the parts.

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.

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.

Using Orbitool increased on-machine cycle times by 45 seconds per part — but decreased time required in the FOD room by about three minutes per part. Across the 2000-part run, this saved the shop about 75 hours.

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.

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.

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.

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.

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

The new insert grades GC1205 and GC1210 cover a large application area within last-stage machining and intermediate-stage machining when turning aerospace engine components.

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.

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.

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.

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

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

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

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

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

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."

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

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.

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

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.

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

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.

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

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.

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.

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?

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

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.

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.

J.W. Done’s Orbitool uses a disk to shield properly finished parts of bore holes, falling away from the wall at the intersection between holes to enable the cutter to proceed with targeted deburring. Photo Credit: Paramount Machine

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

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

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.

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.

All five Solar Atmospheres facilities are now an option for customers with Northrop Grumman requirements for vacuum heat treating.

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

The changes increased the cycle times on the machine by 45 seconds per part — but decreased the time required in the FOD room by about three minutes per part. Across the 2000-part run, this 2.25-minute reduction saved about 75 hours in total process time.

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

Cross-holes have long been an Achilles’ Heel for subtractive manufacturers. As editor emeritus Chris Koepfer of Production Machining once wrote, “despite the best efforts of machinists and programmers, burrs are virtually impossible to eliminate when cross-drilled holes intersect.” In many cases, shops must take an “as good as it will get” approach with parts featuring cross-holes to prevent overlong cycle times that risk customer confidence.

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.

According to Brush Research Manufacturing, abrasive finishing tools do not release large amounts of grit into a machine’s coolant. Hear from three shops using these tools.

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 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.

Luis Rivas was one of the machinists at Paramount who discovered Orbitool through an issue of MMS. He created the Orbitool’s tool path routine, which led to a net savings of 75 hours for a 2000-part aerospace job. Photo Credit: Paramount Machine

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.

After inserting the Orbitool deburring tool into a cross-hole, the user moves the tool until the disk contacts the wall of the hole. Once the disk has made contact and the user has tilted the shaft enough for the axis of the tool to reach the diameter of interpolation, the user rotates the tool and feeds it further into the hole using a helical interpolation routine. The attached disk is slightly larger than the cutter to keep the cutter’s abrasive surface from contacting the hole walls until the tool reaches the burr.

CoroMill MS 20 is designed for repeated shoulder milling, face milling, linear and helical ramping, full slotting and plunging applications.

J.W. Done says Orbitool functions like a conventional cutting tool, mounting into the toolholder of a lathe or machining center. What makes Orbitool unique is its ability to conduct in-process deburring of cross-drilled holes by using the hemispherical shaped cutter on the end of a flexible shaft.

Optimization of machining parameters for turning operation of heat-treated

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