Cutting Tools for Use with New Aluminum-Compound Materials - sandvik solid carbide end mills

 2024-07-01 22:42:18

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.

Hoffmann Group USA has expanded its tool family for Parabolic Performance Cutting (PPC) to include a new PPC indexable insert and Garant PPC solid-carbide barrel milling cutters for high-alloy and hardened steels. The PPC process represents a further development of ball-nosed slot drill cutting and is also known as barrel milling. It is primarily used for finishing free-form surfaces in machining tool building, tool manufacturing and die making and achieves either up to nine times shorter processing times or a significantly improved surface quality.

Sunnen Products Co. is celebrating its 100th anniversary, highlighting the history of its line of honing and precision solutions.

With its new PPC indexable insert which is compatible with the Garant precision copy milling cutters as tool bodies, the Hoffmann Group is launching an alternative to PPC solid-carbide barrel milling cutters with a straight or stub point conical-shaped main cutting edge onto the market. The PPC cut-off inserts are suitable for processing flat faces and freely accessible surfaces without interference contours on the 3-axis machine and are available for steel, high-alloy and hardened steels, stainless steel and aluminium. Garant precision copy milling cutters, which are suitable as tool bodies, are available in steel and solid-carbide versions, including a Garant PowerCard.

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

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.

New tech center is serving as a cutting-edge showroom and a technological hub for advanced machining applications.

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

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

The Walter Turn toolholder features rake-face cooling to help break and control chips, and double flank-face cooling directly at the cutting edge to extend tool life.

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.

Four-flute ceramic end mills are available in cutting diameters from 3/8 to 3/4 inch. Stability is a requirement for using the tools well. The flute design for minimizing vibration is thus an important part of the engineering.

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

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.

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?

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

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

That innovation multiplied the life of these ceramic tools by a factor of 10, and led to the company’s WG300 family of turning inserts.

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

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.

Women in Manufacturing is excited to announce that the 2024 SUMMIT will be a hybrid event — both an in-person and virtual experience. Both program offerings will enable you to grow through education and connections that are insightful, meaningful and actionable. Join Women in Manufacturing Oct. 6-9, 2024, in Boston or digitally for an event filled with plant tours at leading manufacturing facilities, professional development sessions, roundtable discussions on important topics, and inspiring keynotes. All while engaging and interacting with peers through social and networking events! __PRESENT __PRESENT

Like other ceramics, this tool cuts dry and likes high cutting speeds. The crucial difference: The new phase-toughened solid-body tool performs well at cutting speeds that are low for ceramics, coupled with feed rate that is relatively high. The result is a solid ceramic round tool well suited to the capabilities of standard machining centers. All photos courtesy of Greenleaf.

(Memory lane: My first job in industry was in a machining laboratory where we evaluated cutting tool performance in aerospace alloys. I spent a lot of time looking at WG300 inserts’ cutting edges under a microscope.)

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.

Mastercam 2025 incorporates big advancements and small — all based on customer feedback and the company’s commitment to keeping its signature product best in class.

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.

Machining operation in which metal or other material is removed by applying power to a rotating cutter. In vertical milling, the cutting tool is mounted vertically on the spindle. In horizontal milling, the cutting tool is mounted horizontally, either directly on the spindle or on an arbor. Horizontal milling is further broken down into conventional milling, where the cutter rotates opposite the direction of feed, or “up” into the workpiece; and climb milling, where the cutter rotates in the direction of feed, or “down” into the workpiece. Milling operations include plane or surface milling, endmilling, facemilling, angle milling, form milling and profiling.

Thoughtful considerations will set you on a shortened path to the most optimized solution once cutter meets metal.

4150 steel machining in action. The workpiece here is hardened to 54 HRC. The solid-body ceramic milling tool is 0.75 inch diameter. Cutting speed is 1,500 sfm. Feed rate is 0.001 ipt for a full-diameter slotting pass at 0.125 inch axial depth of cut, and 0.0024 ipt for a profiling passes at 0.125 inch axial depth of cut and 0.060 inch radial depth of cut.

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

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.

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

The MB45 series is designed to deliver the low cutting force benefits of positive inserts and the fracture resistance of negative inserts.

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

In addition to the new PPC indexable insert, the Hoffmann Group has optimized three versions of its PPC solid-carbide barrel milling cutter for hard machining. The new tools have a tangential, conical or stub point conical form and are suitable for finishing flat faces and large surfaces with interference contours, as well as deep and hard-to-access cavities. Due to these qualities, they show their full potential on the 5-axis machine. The new Garant PPC indexable milling inserts are also available to users for finishing components made from high-alloy or hardened steels with freely accessible surfaces without interference contours.

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

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.

Yet even at a lower speed than is typical of a ceramic milling tool, the company says its testing in materials such as the aerospace alloy Inconel 718 still shows better metal removal rates and tool life than existing ceramic round tooling. This, too, is because of the freedom of toughness. The lower speed can be matched to a feed rate about 3.5 times that of what existing ceramic end mills accommodate. The result is an inch-per-tooth (chip load) feed rate equivalent to that at which the shop might be accustomed to programming carbide, yet at a much higher spindle speed than would be appropriate for a carbide tool.

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

In the late 1800s, a new technology — Swiss-type machines — emerged to serve Switzerland’s growing watchmaking industry. Today, Swiss-machined parts are ubiquitous, and there’s a good reason for that: No other machining technology can produce tiny, complex components more efficiently or at higher quality.

Are AMRs the next big trend in job shop automation? System 3R’s IMTS booth will emphasize both its specialty EDM tooling and its automation products, including an autonomous moving robot.

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.

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

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

ANCA CNC Machines is celebrating its 50th anniversary as a global producer of CNC tool and cutter grinders.

Mitsui Seiki USA Inc. appoints Joseph Farkas as its director of sales West and Terry Ritterbush as its director of sales East.

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.

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.

Ceramic cutting tools offer a model case for appreciating the distinction between hardness and toughness. These very hard tools have long been a solution for machining very hard metals such as aerospace alloys. However, turning has been their principal application, because of a relative lack of toughness. The tools stand up to consistent high forces such as the steady cut in uninterrupted turning — thank you, hardness — but they are vulnerable to the bang-bang-bang shocks of an interrupted process such as milling, because enduring shocks is what toughness is all about.

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."

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

Moving from cut tapping to form tapping for a notable application cut tooling costs at Siemens Energy and increased tool life a hundredfold.

It was a solution realizing greater toughness that drove Greenleaf’s first big breakthrough with ceramic tools, decades ago. The company introduced ceramic tooling in 1973, manufactured thanks to hot pressing technology that was proprietary at the time. But in 1985, the company proved and went to market with its method for adding reinforcing crystals grown in long, thin strands — known as whisker reinforcement — within the microstructure of the hard turning tools made this way.

Hardness and toughness together mean slow progress of tool wear. The edges of the 1/2-inch diameter ceramic end mill here show the wear after 72 minutes of milling for 64 cubic inches of material removal in 4150 steel with hardness of 52-55 HRC.

Material advances have produced a ceramic end mill that performs well at lower cutting speeds and competes with carbide in a broad range of applications. Your shop might begin using ceramic tools.

Fryer Machine Systems Inc. presents its TC Series of CNC machining centers for high-performance cutting, accuracy, reliability and ease of use.

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

User-friendly inspection software for CNC machining centers is shown monitoring measurements between and after machining while performing SPC based on recorded measurement values.

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.

Loosely, any milling tool. Horizontal cutters take the form of plain milling cutters, plain spiral-tooth cutters, helical cutters, side-milling cutters, staggered-tooth side-milling cutters, facemilling cutters, angular cutters, double-angle cutters, convex and concave form-milling cutters, straddle-sprocket cutters, spur-gear cutters, corner-rounding cutters and slitting saws. Vertical cutters use shank-mounted cutting tools, including endmills, T-slot cutters, Woodruff keyseat cutters and dovetail cutters; these may also be used on horizontal mills. See milling.

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.

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

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

Misapplication of these important CNC features will result in wasted time, wasted or duplicated effort and/or wasted material.

Replaceable tool that clamps into a tool body, drill, mill or other cutter body designed to accommodate inserts. Most inserts are made of cemented carbide. Often they are coated with a hard material. Other insert materials are ceramic, cermet, polycrystalline cubic boron nitride and polycrystalline diamond. The insert is used until dull, then indexed, or turned, to expose a fresh cutting edge. When the entire insert is dull, it is usually discarded. Some inserts can be resharpened.

Structured light scanning is used to create a digital twin of a manufactured part, but we must understand the measurement reproducibility to best use the data.

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.

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.

Thoughtful considerations will set you on a shortened path to the most optimized solution once cutter meets metal.

However, within the many shops able to achieve this level of stability and control, this tool is now a competitor to carbide in a way that ceramic round tools have not been before. The level of toughness resulting from the phase toughening has brought us to this point of change: In facing their challenges with hard metals, many shops will now consider ceramic milling tools that have never used tooling made of this material before.

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.

Pairing automation with air-driven motors that push cutting tool speeds up to 65,000 RPM with no duty cycle can dramatically improve throughput and improve finishing.

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.

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.

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.

Against carbide, the company reports productivity improvement on the order of a factor of 10 in milling hard steel, aerospace heat-resistant superalloys, compacted graphite iron and various hard alloys that are now finding use in production parts made through additive manufacturing processes such as laser powder bed fusion.

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

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).

All new Garant PPC indexable inserts, including tool bodies and the new GARANT PPC solid-carbide barrel milling cutters for hard machining, are available immediately. The precondition for PPC is a CAD/CAM software coordinated to the milling strategy, which allows the tool geometries to be processed as a data model.

SSP’s commitment to adopting the latest machining technology benefits not only the business, but its employees as well.

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.

That productivity improvement does need the right setup. The Xsytin 360 milling tools making use of the phase-toughened ceramic are not a replacement for carbide; we have been speaking of toughness, and carbide is still the tougher material. The ceramic end mills capable of lower speeds still need effective process controls against shocks to the tool — controls that include rigid fixturing; short overhang in the tool setup; a shrink-fit, press-fit or hydraulic toolholder for low runout; and a tool path ensuring continuous cutting by maintaining a consistent chip thickness. Indeed, the tool’s flute design is part of this formula and another important part of the engineering of the tool. This flute aids stability through a geometry that has been refined to minimize vibration. Also needed in the application of the tool: a way to clear chips from the path of the cut without coolant, because this ceramic, like earlier ceramic tools, does far better running dry.

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.

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.

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

Attend TASC, The Automated Shop Conference, in Novi, Mich on Oct. 11, 2023 for a comprehensive look into how to use automation to transform your machine shop.

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.

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

Pairing a shoulder mill with a five-axis machine has cut costs and cycle times for one of TTI Machine’s parts, enabling it to support a niche racing community.

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

Now, ceramic cutting tool maker Greenleaf says innovations in the toughness of ceramics within the last five years offer the potential to dramatically expand the applicability of ceramic tools in milling. The company recently launched its “Xsytin 360” line of solid-body four-flute ceramic end mills, after two years of development. According to James Greenleaf, the third-generation owner of the company, these tools are “the most extensively tested product we have ever introduced.” And that testing continues, because a ceramic tool with greater toughness is a tool that potentially has promise within machining sectors and applications not typically associated with ceramics, involving shops that have not turned to ceramic tooling before.

Refined machines at EROWA are handling heavier loads, while its precision workholding enhances stability and rigidity.

New tech center is serving as a cutting-edge showroom and a technological hub for advanced machining applications.

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.

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!

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 Xsytin 360’s SiAlON (a ceramic combining silicon, aluminum, oxygen and nitrogen) is a material about which James Greenleaf feels he can confidently say, “This is the strongest ceramic material on the market. We finally felt we had a ceramic good enough to offer a really effective round tool.”

Effective team collaboration is a critical component of success in today’s manufacturing world. With cloud-based technologies that make it easy for team members to brainstorm and problem solve remotely from various locations, design-to-manufacturing processes can become faster and more efficient. This webinar will demonstrate how fully integrated CAM software can be utilized with 3DExperience SolidWorks in a seamless work environment to accelerate product development. Agenda: See how HCL CAMWorks can be used as an add-in for all SolidWorks applications working with the cloud-based 3DExperience platform Learn how fully integrated CAD/CAM saves significant amounts of time during the design to manufacturing process Gain a new understanding of how software can connect users worldwide to accelerate product development Watch a demonstration of team collaboration using platform tools in the CAD/CAM software environment

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

Ceratizit USA announces it has appointed Carlos Garza as its business development leader for the oil and gas industry sector.

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.

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.

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.

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

Are AMRs the next big trend in job shop automation? System 3R’s IMTS booth will emphasize both its specialty EDM tooling and its automation products, including an autonomous moving robot.

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

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.

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

The company also applied ceramic inserts to milling, albeit on larger-diameter tools. But now, the latest major advance in ceramic toughness has led the company to introduce smaller-diameter solid tools as well as inserted ballnose tools. This latest toughness advance is not because of the addition of a different reinforcing mechanism, but rather because of a proprietary phase toughening process that leads to greater control over the formation of the ceramic material, including the formation of the whiskers. As the company explains, phase toughening of the material delivers a stronger material substrate as well as more predictive performance in applications where other cutting tool ceramics are prone to failure. The material made this way still favors hardness over toughness, but now within a combination that not only provides for the requirements of smaller-diameter tools, but also lands nearer to the needs of general machining and to the performance capabilities of more mainstream machining centers.

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

Thoughtful considerations will set you on a shortened path to the most optimized solution once cutter meets metal.

In test cutting, the performance and promise of the new round tools have been seen not principally in the high speeds these tools are able to achieve, but instead — stay with me on this — important improvement has been found at the low speeds at which these tools cut well. Ceramic tools are generally run at very high speeds (and run dry) because the ceramics’ thermal coefficient makes the tools so heat-resistant. The tools even have minimum cutting speed thresholds for optimal performance. However, the new, tougher ceramic tools do not need the intensity typical of ceramics. The optimal speed range for the new solid ceramic end mills begin at 1,300 sfm, low compared to other ceramic cutters. For a 1/2-inch end mill, that is about 10,000 rpm. In short, the needed speed is accessible to a broad range of machine tools used by a broad range of shops.

Compared to carbide end mills, the ceramic tool can realize both a much higher cutting speed and a much higher feed rate for a higher metal removal rate overall. Shown here are parameters for machining Inconel 718. Note the ceramic tool’s speed, which, while high, translates to only about 12,000 rpm.

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

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

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.

Cutting Tools for Use with New Aluminum-Compound Materials - sandvik solid carbide end mills

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