Square End Mills - 1 1/4 end mill

 2024-09-13 20:49:42

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.

Tool-holder-spindle-machine combinations each have a unique dynamic response in the same way that each person has a unique fingerprint, which can be revealed using modal testing.

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

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

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.

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.

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.

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

In addition to the steel blend itself, Milwaukee also includes a “Shockzone” in their bits. This area is very obvious as the narrower zone in the middle of the bit. It allows for additional flexing to buffer the bit from torque while still giving the tip the chance to rotate and further drive the fastener.

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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

The most basic idea when looking at impact rated bits versus standard bits is to look at the differences in design. It starts with material itself. Milwaukee blends a custom steel that provides more ductility than in their standard bits. If you think back to high school chemistry, ductility is the ability of a solid to deform under stress from tension. Most of us were introduced to this using the example of metal being stretched into a wire. For impact rated bits, this ductility gives them the ability to twist and flex under stress from the torque of the impact driver.

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

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

I can openly say that I think all professionals should have a set of impact rated bits and nut drivers like the Milwaukee Shockwaves in their tool box along with an extended reach bit holder or two. It would benefit most homeowners that keep an impact driver handy to have a set as well. Understand both the expectation of performance and the cost though. Don’t use them if the application doesn’t call for them. Just because you’re using an impact driver doesn’t mean that you need to use impact rated bits. Save those more expensive accessories for when the situation makes sense to bring them out.

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.

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.

This out-of-sync condition can occur instantly, and once it starts, the tool and workpiece begin bouncing off one another more forcefully with each passing of the flutes across the workpiece. This worsening condition is detectable as chatter. “A machinist can hear the rise and fall in the sound of this chatter as the frequencies go in and out of phase,” he says.

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

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

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.

Milwaukee makes the Shockwave lineup of impact rated bits and accessories. In addition to getting feedback from their technical folks, I also got my hands on Shockwave bits, nut drivers, extended bit holders, and 30 Degree Knuckle to work with.

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!

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

In these two pictures, take a look at the difference between low speed/low torque cam out and high speed/high torque cam out. With lower forces, the bit transfers the majority of the damage to the fastener head compared to the new one. In the high speed test, the bit took much more damage and the fastener took less. This is an issue for both impact rated and standard bits.

This new quick-change tooling system enables shops to get more production from their Swiss turning centers through reduced tool setup time and matches the performance of a solid tool.

I read very few studies that found bit breakage as the failure. Virtually all of them listed bit rounding as the point where the bit was considered failed. Many suggested that the point of failure is when three cam outs were experienced in a row. If we think about it, the softer (more ductile) bit should round faster! With this testing method, all but the worst standard bits are going to outperform impact rated bits.

Kenny holds a B.S. in Biology and a minor in chemistry. While that might not sound like a direct line into the power tool industry, his analytical and scientific mindset helps him design repeatable testing methods for Pro Tool Reviews’ head-to-head testing and offers highly objective comparisons in his reviews.

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

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.

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.

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.

There are a couple of reasons that impacted rated bits will still fail. The first is shared with standard bits. When the bit slips in the fastener head (affectionately called cam out), the fastener head becomes noticeably damaged. What isn’t as obvious is that the bit tip is also becoming damaged. Each time cam out occurs, the tip becomes more and more rounded until it can no longer effectively drive. Two ways to avoid this are to ensure that you are selecting the correct size bit to match the fastener and ensuring that you are putting enough force against the fastener to ensure the bit stays engaged.

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

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).

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

I have come across this question dozens of times. I’ve read article after article and review after review touting that impact rated bits are a scam, not worth the money, no better than standard bits, and more. Customer reviews slam these accessories as an unnecessary expense developed by manufacturers as a way to make more money. We even published an article about impact rated bits and found that Bosch’s standard bits outperformed all of the impact rated ones we tested based on our methodology. Read our original article Are Impact-Rated Bits Worth the Money? So why even bother revisiting this idea?

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Keeping vibration in sync to avoid negative consequences does impose certain requirements on the machining process. According to Mr. MacArthur, the tool must be used with flood or through-tool coolant to keep chips from interfering with the action of the Mirror Edge. The tool works best in aluminum, because the high spindle speeds used for cutting this material tend to create higher cutting frequencies than those encountered at lower spindle speeds when machining harder materials such as steel or titanium. (However, Mr. MacArthur notes that the Mirror Edge can be added to end mills customized for specific applications in these materials, although other vibration-control techniques are likely to be needed for full effectiveness in these cases.) End mills with Mirror Edge can be used at the machine tool’s highest spindle speed in aluminum without any chatter. This enables the feed rate and metal removal rate to increase substantially. Stepovers that are 50 percent of the tool radius are recommended, along with chip loads equal to the tool diameter times 0.016-inch per flute.

For most fastening applications, no, you don’t. Unless you’re doing the applications mentioned above or others that push your impact driver to really drive to its potential, you’ll actually get better performance from the standard bits. There is room in your tool box for these bits and accessories though. Sooner or later you’ll come across the need to break loose a stuck nut, drive a screw into metal, or drive a large lag bolt.

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

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

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

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.

Mr. MacArthur says that applications with deep pockets and/or thin walls are the most suitable for these end mills, however, certain programming techniques are in order for machining thin walls. For example, each Z level of a pocket should be roughed and finished before proceeding to the next, lower Z level. Sufficient stock should be left on the walls for the finishing pass to maintain rigidity. This stock helps support the wall ahead of the cut. Applying constant-chip-load pocketing routines in the CAM program is also recommended. He says walls as thin as 0.005 inch and as tall as 3 inches can be produced effectively in this manner. The resulting wall will be straight and smooth.

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

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

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.

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

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In a machining process, vibration causes chatter. More specifically, chatter occurs when the workpiece and the cutting tool are vibrating at different frequencies. Literally, the workpiece is moving in one direction while the cutting tool is moving in the other direction. Of course, these relative motions are slight and happen at many times a second. Chatter is the resultant sound of the workpiece and the cutting tool knocking into one another at a high rate. This knocking does more than make an irritating noise: It also damages the tool, degrades the workpiece surface, harms the spindle and may leave part features out of tolerance.

Perhaps a more significant benefit is the substantial increase in metal removal rates that Mr. MacArthur reports for these end mills in aluminum. “A fivefold increase in metal removal rates compared to traditional end mills is possible,” he says. “Removing as much is 42 cubic inches of material per minute can be attained with significant increases in tool life to boot,” he adds, noting that walls thinner than 0.020 inch limit removal rates to accommodate the smaller stepdowns in Z that are required.

This is the million dollar question – and it has everything to do with testing methods. If we put up impact rated bits against standard bits using a 4 inch deck screw into pressure treated lumber, we’re in the standard bits’ happy place. The standard bit never reaches anything close to its failure point, even with an impact driver. Most reviews that I read have the impact rated bits reaching their failure point first.

I’ll admit, I’m a pretty loyal guy. I don’t know everyone at every tool manufacturer, but I do know that the ones I’ve had a chance to get to know don’t produce garbage and keep it on store shelves. So I set out to discover what the real deal is with impact rated bits. Knowing the depth of the Research & Development and Engineering teams at Milwaukee Tool, I enlisted their help in uncovering the mystery. They graciously took the time to answer my questions and allowed me to get an idea of the technical side of these accessories.

This end mill design enables it to vibrate at the same frequency as the workpiece, preventing vibration from turning into chatter.

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

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

If you want to use a high speed milling spindle to machine aggressively, then information about chatter should be more than just background noise. Here are some basics.

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

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

Mr. MacArthur says this added edge is just enough to keep the flute in contact with the workpiece until the next flute is engaged (the end mill has three tightly spiraled flutes for this reason). This highly polished edge minimizes frictional rubbing, so it creates virtually no heat and does not alter the workpiece surface. The constant contact prevents both the tool and the workpiece from “going their separate ways” in response to various forces inducing vibration. Thus, the tool and workpiece keep moving in unison to maintain synchronization regardless of the frequency of the vibration. Neither the tool nor the workpiece can “bounce away” from the other and fall into a different rate (frequency) of vibration, Mr. MacArthur says.

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

Consistency is key for beryllium manufacturing, so the data visibility granted by Harmoni has swiftly become a vital, profitable tool in the shop’s arsenal.

The next discussion is about metal fatigue. Grab a paper clip and bend it. Now bend it back. The metal has enough ductility to reshape under the stress you’re putting on it. It takes a toll though. Continue the same back and forth motion. Eventually, the metal will weaken and break. Touch the area where it failed immediately and you’ll notice that it’s warm. This is what metal fatigue does. The movement is able to absorb the stress for a certain amount of time, but not indefinitely. As the impact rated bits flex, they are experiencing metal fatigue which is not something that can be undone with rest. Eventually it will break.

The DeWalt DCF870 20V Max Hydraulic Quiet Impact Driver is a long-awaited addition to DeWalt’s most popular battery platform. Has […]

Pro Tool Reviews is a successful online publication that has been providing tool reviews and industry news since 2008. In today’s world of Internet news and online content, we found that more and more professionals researched a large majority of their major power tool purchases online. That piqued our interest.

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

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

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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.

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.

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

Threading tools with the flexibility to thread a broad variety of holes provide the agility many shops need to stay competitive. They may be the only solution for many difficult materials.

Now grab a pencil, preferably one you don’t intend on using again. Gently bend it, but not too much. You’ll notice it will flex, but not nearly as much as that paper clip did. Go ahead and put some more force into it. The fact that it broke without bending as much as the paperclip shows that it is less ductile (if it were metal). It can’t reshape as easily and instead breaks immediately under pressure.

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.

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A set of donated boring bars that can be used in a 1954 boring head will enable volunteer machinists to recreate a pair of binoculars for the USS Pampanito.

The Milwaukee Shockwave impact rated bits are designed to outperform standard bits when the maximum torque of the driver is applied. We’re talking the kind of torque that snaps a standard bit on the first try. Most fastening jobs don’t come anywhere near that force. To get to the point where the impact driver is delivering torque to its potential, we’re talking about metal to metal fastening where high torque is required to break the friction between the metals. We’re talking about hard stop fastening where you reach the end and the driver delivers all of its torque it has to tighten it down. We’re talking about long lag bolts where the driver delivers not only high torque, but for an extended time and really pounds at the nut driver. These are the kind of applications that standard bits and nut drivers can’t hold up to and snap, usually at the tip or shaft where they are weakest.

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

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.

Mike MacArthur, vice president of engineering at RobbJack, explains that the end mill design includes a special edge preparation that creates an additional surface along the trailing side of each spiraled flute. The company calls this additional feature the Mirror Edge, because it is highly polished and shiny. This added edge is 0.001- to 0.002-inch wide, so it can barely be discerned by holding the tool and slightly turning it in the light. The first photo in the slideshow above captures the slender band of light reflected by this edge as indicated by the arrow. The other reflections alongside it are, respectively, the land and the cutting edge of the flute normally found on a spiraled end mill.

A HUGE thank you goes out to the Engineering Team, R&D Team, Project Managers, and Kharli Tyler at Milwaukee Tool for the work and research they put in to developing the Shockwave lineup of impact rated bits and accessories as well as putting up with my curiosity and desire to understand the technical details of that work!

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

This photo and the next compare a pocket showing the effects of uncontrolled chatter (next photo) with a pocket machined with an end mill that controls chatter with the Mirror Edge feature.

While it’s not perfect, the paperclip and pencil demonstrate the difference between standard and impact rated bits. Standard bits can be made very strong, but the trade off is that they are more brittle. When they have the extreme torque of an impact driver placed on it, it snaps quickly. The impact rated bits blend strength and ductility to continue driving while it absorbs the torque. Eventually, it will succumb to metal fatigue, but it will last a lot longer under that stress.

According to RobbJack, the Mirror Edge feature helps stabilize the end mill’s contact with the workpiece surface to synchronize the vibration of the cutting tool and the workpiece.

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The ability to cut thin walls that are straight, smooth and accurate is one of the benefits of using an end mill that damps vibration effectively.

The engineers that designed the Milwaukee Shockwave bits are smart – really smart. A lot of testing went into developing a steel blend that will absorb that torque and withstand metal fatigue for an impressively long time. Finding a balance between flex for absorption and strength to drive is no simple task, but the result is that the Shockwave impact rated bits experience failure from metal fatigue much later than a standard bit would snap. In fact, under that kind of stress, Milwaukee Shockwave bits will survive up to 10 times longer than standard bits.

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

When it comes to driving screws and you need to make a decision, the general rule of thumb is to use standard bits on wood and impact rated on metal.

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

Cutting tool manufacturer RobbJack has a strategy for dealing with chatter that is based on the concept of getting the cutting tool and the workpiece to vibrate in the same direction at the same rate. To this end, the company has developed an end mill design (primarily for milling aluminum at high feed rates) that gets the cutter and the workpiece to synchronize the frequency of vibrations during machining. This does not stop the vibration, but rather stops the knocking caused by out-of-sync vibrations. Apparently, when the knocking goes away, so do the other unwanted side effects.

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.

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

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.

Currently, the Mirror Edge preparation is available on RobbJack’s A1-303 and FM series aluminum end mills in diameters from 1/8 to 1 inch on standard tools, and on tools as small as 0.010 inch in diameter on special order.

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

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.

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.

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.

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.

Square End Mills - 1 1/4 end mill

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