Taking Stainless Steel Machining to the Next Level - cnc tool insert material

 2024-07-06 18:03:09

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

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.

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

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.

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

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.

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.

Additionally, the insert can maintain a high degree of rigidity thanks to the design of its dovetail profile in the insert pocket. The dovetail connection relieves tension from the clamping screw while simultaneously reducing movement. The insert is connected axially and radially, and the flanks of the insert are tapered to provide further support. All these features combine to provide a highly rigid insert, which can decrease runout, improve the finish, reduce wear on the inserts and increase the feed rate. “A good cutting tool is not just about the cutting-edge geometry,” Stusak says. “Many different features come together to create an insert that has the cutting-edge profile, clearance, rigidity, and material removal rate needed for the task at hand.” Even the 8-millimeter IC size of the insert plays a role, as it provides room for more inserts around the tool’s circumference, thus boosting productivity.

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.

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

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.

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

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.

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

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

It is also worth emphasizing that this is not a nearly 90-degree cutter, but a true 90-degree cutter. “There are other square inserts that provide an 88- or 87-degree lead angle,” says Stusak. “This means that after roughing the part, the user has to go back over it to achieve the 90-degree angle required by the specs.” The NEO-DO S890 enables the operator to perform a roughing and finishing pass on the part without having to change tools or go back over the same passes again. This saves both time and cost.

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

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).

One easy-to-control factor that can improve the reliability and accuracy of milling these features is the cutting tool. Cutting tools with 90-degree lead angles generate radial cutting forces that transfer more of the cutting energy away from the part. This makes them ideal for parts with thinner walls or near-net shapes, as well as for parts with less rigid fixturing. Knowing that near-net and 3D-printed parts are growing more common, Iscar recently developed a square insert designed for finishing complex parts.

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

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?

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.

The NEO-DO S890 is a 90-degree, double-sided, square milling insert from Iscar designed for combination applications, i.e., face and shoulder milling, and finishing near-net shaped components. “One of the challenges of designing a true 90-degree square insert is having enough axial clearance on the bottom of the insert so you’re not rubbing too much,” says Iscar National Product Manager - Milling, Bryan Stusak. “The geometry of this insert enables a true 90-degree angle while increasing the number of edges per insert over our previous offerings.” The true 90-degree angle, combined with a 0.200-inch maximum depth of cut makes this ideal for making finishing passes, especially on complex parts. “Printed and near-net shaped parts have very little material to remove,” says Stusak. “This insert is ideal for that environment, as it enables the cutter to make precise passes while minimizing the potential for damaging the part especially where there are workpiece or work holding fixture constraints.”

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.

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.

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

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.

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

While the NEO-DO S890 is currently able to cut ISO P and ISO K materials, the company plans to expand its range to more difficult metals.

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

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.

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 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.

Edge preps for the NEO-FEED come in HP for stainless steels and exotic alloys, as well as in T-Land for general-purpose machining. As with the NEO-DO, the NEO-FEED benefits from the rigidity of the dovetail pocket design and the cost-per-edge of double-sided square inserts.

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.

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

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

In 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."

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

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.

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

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

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.

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

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.

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.

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.

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.

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.

Iscar has also recently developed double-sided square inserts for its high-feed NEO-FEED line. “The industry is trending toward high-feed milling to take advantage of improved material removal rates,” Stusak says. “We developed the NEO-FEED to accommodate this need.” The NEO-FEED insert can work with one of two cutter body designs.

Currently, the NEO-DO S890 only has one edge geometry, which is suitable for ISO P and ISO K materials. “We will be adding a high-positive (HP) geometry,” Stusak says. “This will be suitable for difficult-to-machine materials such as stainless steel.” However, ISO P and ISO K materials make up a hefty portion of automotive manufacturing, the primary market this tool is designed to serve. The inserts come in a T-Land edge preparation for cast iron and an MM edge prep for steels.

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.

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

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

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.

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!

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.

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

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

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

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.

Choosing the right milling insert is important: This insert from Iscar is designed for finishing near-net shaped parts quickly, while another makes high-feed machining more accessible with existing machining centers.

The NEO-DO S890 is designed to enable the operator to perform both roughing and finishing passes without having to change tools. The small inserts are ideal for making precise passes on parts with near-net shapes.

As a double-sided square insert, the NEO-DO S890 has more cutting edges than any other 90-degree milling insert Iscar provides. This makes it an economical choice for finishing near-net shaped parts..

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.

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.

Of course, a major benefit from developing the NEO-DO S890 as a square insert is the cost savings. “Of all our 90-degree inserts, this has the lowest cost per edge,” says Stusak. “This is especially important for high-production environments.” The company’s many other 90-degree insert offerings are rectangular, triangular, and trigon in shape, meaning there are only four-to-six edges per insert compared to the NEO-DO’s eight.

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

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

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.

The NEO-FEED inserts are designed to work with both a high-feed and medium-feed cutter. The medium-feed cutter in particular is designed to bridge the gap between traditional face milling and high-feed milling.

The automotive industry has embraced light-weighting, increasingly looking for manufacturers capable of producing near-net shaped parts, either from precision forged metals or in finishing processes for additive manufacturing (AM). Complex part designs are quickly becoming standard, but as much as complex shapes can benefit the final product, these shapes are thinner than those of most prismatic parts, which means there is less wiggle room in the cutting forces a machine applies to the part.

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

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.

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.

The first cutter body design is a “fast-feed” cutter that enables the user to tilt the insert at a 12-degree lead angle to the surface. “This enables the cutter to have what they term as an axial chip-thinning effect,” Stusak says. “This gives you a 0.060-inch depth-of-cut capability.” This provides ideal conditions for high-feed milling processes.

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

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.

Sumitomo Electric Hardmetal has expanded its DGC double-sided insert face milling cutter body range to accept SNMU square eight corner inserts or more economical 16-corner ONMU type in the same body pocket.

For shops that do not have the advanced machine tools necessary to maintain extremely high feed rates, the company also make a moderate-feed cutter offering. This cutter uses the same NEO-FEED inserts, but with a 22-degree lead angle resulting in a 0.118-inch depth of cut. “The increased depth of cut partially compensates for the lower feed rate when it comes to material removal,” Stusak says. “This is really a hybrid option of a high-feed tool and a face mill. It won’t reach the feed rate of the high-feed tools, but it is certainly faster and more aggressive than a traditional 45-degree face mill.”

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.

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

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

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

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

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

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

Manufacturing is a competitive industry in which machine shops across the world struggle to make parts more efficiently than their neighbors. This leads to new technologies improving machine performance often creating more complex parts for shops to cut. In this environment, something as simple as knowing the right cutter for the right job can give a shop the edge.

Taking Stainless Steel Machining to the Next Level - cnc tool insert material

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