Stepped nipples are very versatile: Due to their form, they can be used not only in materials of different thicknesses. They can also be used for cables of different thicknesses, as they can be used in several steps and thus the ideal diameter for its cables and wires. receives.

The tool’s dual functionality comes from its design, which incorporates three cutting edges to remove material and three burnishing edges to compact the material. This produces polished mirror surfaces as fine as 0.08-μm Ra.

“Cut & Form end mills are another example of innovative technology at work [that has been] designed to dramatically speed machining throughput, eliminating time, secondary operations, and cost,” said Bob Hellinger, president of Emuge Corp.

For this we use our GSR PROFI electric step drill. In addition to the steps in mm, this drill has dimensions for armoured pipe threads (PG).

The other important item to note is the substrate of the tool. It is made from solid carbide, which is very hard, and too much force on the tool can prevent the optimal surface finish from being attained in harder materials.

With the step drills from GSR, no additional tools are needed to drill the through hole: centering, tapping, reaming and deburring are all done in a single operation.

For electrical installations it is often necessary to install cables or to lead hoses out of or into a housing. For this purpose the Cable safely and sealed by the housing material (usually a thin sheet of metal or thin plastic) through it. To do this, one uses so-called Cable glands.

The application areas of a step drill are very diverse. They are especially good for the installation of cable bushings to use!

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Finally, insert the step nipple into the hole. With a little pressure you can push the first sealing ring through the opening – then the bore should be comfortably enclosed by both rings. The step nipple should not wobble or even slip out, because then the bore is too large.

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“The development stemmed in part from a customer in the communications industry who was looking to finish the exterior of an aluminum housing and wanted a polished surface that did not require any additional polishing after the milling process,” said Doiron.

First measure the step nipple with the aid of the slide gauge. This is done in 2 places: first measure the wider of the two sealing rings. This gives you the dimension which the diameter of the bore must not exceed. Then measure the recess between the sealing rings – this is the minimum dimension of the bore diameter.

Step drills are the specialists for drilling into thin materials of max. 4 mm thickness. One of the many applications of this tool is the installation of cable bushings. The following article will show you how to do this!

“The higher the tensile strength, the more critical it is in the compaction of the material,” said Doiron. “Nonferrous materials have a lower tensile strength that requires less cutting force than that of steel or hardened materials.”

Typically, finishing operations, depending on the required finish, take the most time to complete. However, a new product may help reduce some of the fine-finishing time required to achieve a polished surface after cutting.

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Very important: prepare the drill with cutting oil so that the drill does not run hot and the tool life of the tool is maintained.

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Cable bushings are available in many different variations. Whether bushings for desks or membrane grommets for sealing cable exits – for every application there is a suitable Cable gland. Today, however, we are dealing with the so-called step nipples and how to professionally installed.

“This medium is 100 per cent free from other microparticles in comparison to standard emulsion coolant. However, coolant can also be used with success if oil application is not desired,” said Doiron.

“The unique design of the solid-carbide end mills is not only the polished surface quality, but also the surface quality of the pressure ridges. These pressure ridges are designed to compact and smooth the material,” explained Dan Doiron, Emuge milling products manager.

The surface quality is also dependent on the coolant, said Doiron, with optimal results produced using minimum quantity lubricant (MQL) oil.

This is what the installed step nipple looks like from the front and the back. In our example we have left the cable gland intact. Before or after insertion, the step nipple should of course be shortened according to the required cable thickness.

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Once you have found your two measurements, look at the laser marking on the step drill. The step used for drilling should be between the measured dimensions of the step angle in terms of diameter. This ensures that the step nipple fits into the hole and cannot slip out. To be on the safe side, you can also measure the diameter of the desired drill step on the step drill again with the slide gauge.

Emuge Corp., West Boylston, Mass., has introduced the Cut & Form solid-carbide finishing end mill, which features a patented tool geometry that performs two functions -- cutting and polishing -- in one operation.

The geometry of the tool (see Figure 1) has cutting edges that remove material [shown in red] and pressure ridges that compact and smooth the material to produce polished surfaces [shown in green].

An award-winning writer and graduate of the Sheridan College journalism program, he has published articles worldwide in a variety of industries, including manufacturing, pharmaceutical, medical, infrastructure, and entertainment.

Besides the sealing there are further advantages of these Bushings: they also arrange and insulate the cables. Sometimes on But the most important thing is that a strain relief is manufactured. Thus the cables are protected, do not chafe on the edge of the Drill and do not break so easily.

Here is a small tip: After clamping the drill chuck, it is best to mark the step to be drilled with a coloured pen. This way you do not drill too far and can proceed quickly without having to pay attention to the laser marking!

Next, the step drill is clamped into the drill chuck of the cordless drill. Thanks to the practical three-surface shaft, the GSR step drills hold perfectly in the drill chuck and slippage is thus minimised.

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Joe Thompson has been covering the Canadian manufacturing sector for more than two decades. He is responsible for the day-to-day editorial direction of the magazine, providing a uniquely Canadian look at the world of metal manufacturing.

ISCAR is About to Change Metal Cutting…AGAIN. QUICK-X-FLUTE – NEW Innovative Extended Flute Cutters Optimized for Efficient and Cost-Effective Roughing of High-Temperature Alloys and Steel

Machine shops have many options when searching for a solid-carbide end mill. The type of end mill, geometry, and coatings all are selected based on the operation and the material being cut. Then it’s time to rough, and then finish the cut.

With the “cutting” edge, the tool creates a machining process that uses very small stock material (0.004 to 0.008 in.) for the pressure ridges to produce a polished surface.