WHEN SHOULD YOU CHOOSE COBALT DRILL BITS? - hss drill bit meaning

 2024-08-20 17:43:10

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

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.

This was especially true for TNG Energy Services Inc., a geothermal company that provides both equipment and services from its Bakersfield, California, headquarters. The company’s mostly JIT workload along with meeting strict quality control requirements led its employees to work large amounts of overtime. This was due, in large part, to the challenges of machining grooves in valve components for oilfield applications using conventional carbide inserts. By switching to ceramic inserts from Greenleaf Corp. (Saegertown, Pennsylvania), TNG was able to dramatically reduce cycle time for two valve applications, meeting deadlines without the additional overtime costs.

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.

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!

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 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.

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.

Forget “additive versus subtractive.” Machining and metal additive manufacturing are interconnected, and enhance the possibilities for one another. Here is a look at just some of the ways additive and machining interrelate right now.

With the carbide inserts, Mr. Hylton says he had to peck at 0.005-inch depth increments to keep any edge at all. In addition, the retract amount that was programmed into the peck cycle had to be larger than usual due to tremendous amounts of tool pressure. In this case, the actual surface of the cutting tool/workpiece interface was 0.010-inch farther out than the actual machine position. The need to have a 0.012-inch buffer between pecks increased the actual feed travel to 1.498 inches. This meant the machine had to feed a total of six times the actual depth of the groove. The slow nature of this process was exacerbated by the need to peck.

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.

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

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

When it comes to utilizing the spindle’s power, there is a lot of headroom at the upper limits, provided it’s in short bursts. Be mindful of your time at these loads so you don’t stall out.

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

Each valve body features two ring grooves. These features alone would’ve taken two hours to produce on the manual engine lathe during reconditioning applications.

Using Greenleaf’s Ring Max API ring groove cutter with WG-300 whisker-reinforced ceramic inserts helped TNG reduce the time it took to cut one ring groove from about 45 minutes to just 28 seconds.

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.

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.

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?

Another problem was the machine’s low speed. It simply didn’t have the torque necessary to efficiently machine all layers of the material, and it would rumble and beat everything up, Mr. Hylton says. He often used three carbide insert tips during the process, requiring him to stop, pull the insert, change it and hit cycle start again. The entire grooving process took between 47 minutes to an hour to complete. To make matters worse, Mr. Hylton says that sometimes the insert would break randomly; there was no consistency at all.

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.

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.

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

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

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

The ceramic inserts really show their colors during the reconditioning applications, Mr. Hylton says. After the Inconel cladding is applied, he mills down the weld that’s bulging above the flange and follows up with the Ring Max tool, cutting the ring groove in just 28 seconds. Because ring groove machining is a continuous cut, through-spindle coolant is used. The coolant is used not to cool the insert, but to cause the chips to become more brittle and break into smaller pieces, sometimes becoming almost powder-like.

TNG Energy Services Inc. was experiencing inconsistent carbide insert life in valve grooving applications. Greenleaf's Ring Max and face grooving tooling helped to reduce production time and increase reliability.

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.

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

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

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

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

The Inconel cladding that bulges above the valve flange is later milled down and then cut with the Ring Max tool during reconditioning applications. The ring groove is cut in just 28 seconds.

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.

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.

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.

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.

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

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

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

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.

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.

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

To cut out laborious manual processes like hand-grinding, this briquette manufacturer revamped its machining and cutting tool arsenal for faster production.

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.

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

Now, the company uses a face grooving tool with Greenleaf’s new Xsytin-1 ceramic inserts and a support blade. According to Greenleaf, Xsytin-1 is a phase-toughened ceramic insert grade that is showing promise for a wider range of materials than traditional ceramic insert technology, bridging the gap between conventional carbide and ceramic inserts for exotic materials, as well as more conventional metals such as mild and stainless steels. The company says its proprietary phase-toughening ceramic manufacturing process developed for this coating-free grade results in predictable, wear- and thermal-shock-resistant inserts that are twice as strong as the company’s WG-300 whisker grade. It also enables the generation of a sharper insert edge, which can lead to reduced tool pressure and better surface finishes.

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

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

While manufacturing parts just in time (JIT) has many advantages for a shop’s customer, shops oftentimes face challenges with this sort of production schedule. Namely, there’s no wiggle room for meeting deadlines.

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

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

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.

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.

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.

Although WG-300 is designed for excellent shock and wear resistance at high surface speeds for nickel- and cobalt-based superalloys, the grade is a good match for TNG’s application, which runs the materials at a relatively modest horsepower rating (20 hp) on its Hwacheon Vesta 1050B CNC mill.

TNG also uses ceramic inserts on its bread and butter work of cutting valve seats in 410 stainless with a Stellite overlay. According to Mr. Hylton, this application is tricky because the groove goes through the Stellite, then through the heat-affected zone and down to the base material—an application that requires cutting material ranging from 40 to 67 HRC.

Now, Mr. Hylton says the problem is the base material. “Before, I couldn’t wait to get there,” he says. “Now, when I hit the stainless, the chips come off in long strings. The inserts get a little beat up on the sides from the chips because face grooving is a nasty operation.”

The groove is produced in one shot, eliminating the finish pass as well. When TNG started using the ceramic face grooving tool, Mr. Hylton says he was nervous. He questioned his Greenleaf representative about his suggested cutting speeds. However, he says his fears were soon calmed when he saw the Stellite coming off like powder. The ceramic face grooving tool can cut the groove in 30 to 40 seconds.

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

Flute TypeRight handSurface TreatmentZinc finishShank TypeStraight,reduced on diameters over 13mm for use in with a 13mm(1/2") chuck.ApplicationFor drilling holes in masonry, concrete, limestone, natural stone & artificial stone.Tip MaterialTungsten carbide single tip

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

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.

Adopting PCD tooling has extended FT Precision’s tool life from days to months — and the test drill is still going strong.

TNG’s most common work is cutting valve seats in 410 stainless with a Stellite overlay. A face grooving tool with Greenleaf’s new Xsytin-1 ceramic inserts and a support blade help cut through all layers in this application.

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.

Before switching to ceramics, TNG used carbide inserts to produce two API ring grooves on 31/8-inch-diameter valve bodies with a 1963 manual-engine lathe, a process that took between 10 and 15 minutes each to complete. The real challenge, though, was in reconditioning these valve bodies, because it often required cutting through difficult-to-machine materials such as Inconel. For instance, after opening the grooves in the cast steel base material 3/16-inch larger than the API specifications, the valve went to the welding department for Inconel cladding. From there, the process involved opening a straight face groove with a face grooving tool followed by an API ring groove tool. This was only possible by moving into the cut 0.100-inch axially, then moving in a positive and negative radial direction to the groove’s full width. After that, the machinist would move the tool in another 0.050 inch and blend from side to side to match the width of the previous radial cut. These tiny increments were repeated until the full depth of cut was reached. An experienced, efficient machinist like TNG’s lead machinist, Cimaron Hylton, could produce one groove in about 45 minutes, though many days it took closer to an hour.

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.

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

According to Mr. Hylton, taking such small depths of cut was necessary to reduce vibration and chatter, yet it didn’t fully eliminate it. Several times during the grooving process, machinists had to check the pitch diameter to ensure accuracy. They also had to hand-polish the angled groove walls.

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.

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).

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.

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

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

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.

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

Spurred by often unpredictable tool life and lengthy production times, TNG turned to ceramic inserts from Greenleaf. In the ring groove application, the company decided to use the Ring Max API ring groove cutter with WG-300 whisker-reinforced ceramic inserts. Designed specifically for the oil and gas industry, Greenleaf’s Ring Max line of ring groove tooling is engineered to reduce the machining time of API ring grooves, while the basic concept of WG-300 involves reinforcing a hard ceramic matrix with extremely strong, stiff, silicon-carbide crystals, or “whiskers.” The whiskers are dispersed into a matrix of fine-grained aluminum oxide, where they act much like glass filaments do in fiberglass, for example, by adding tensile strength and improving the fracture toughness of the brittle matrix.

Given the productivity gains for just one valve feature, Mr. Hylton has no question about moving forward using ceramic inserts. TNG is even planning on producing two valves per week in the future because of these improvements.

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

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

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.

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.

While the ceramic inserts could potentially be used for more than one groove, he says that he changes them after each groove to be on the safe side. But even at one groove per insert, he says he’s impressed with the predictability and longevity of the ceramic inserts. In fact, he’s quit trying to push tool life in the face grooving operation because the ceramic inserts are comparable in price to the carbide inserts when time savings are factored in.

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

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.

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.

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

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.

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.

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.

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

Mr. Hylton says he’s noticed the Xsytin-1 grade shows significantly less damage when the groove is complete, so he plans to transition the Ring Max application to the new insert grade once he runs through his batch of WG-300.

WHEN SHOULD YOU CHOOSE COBALT DRILL BITS? - hss drill bit meaning

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