Whether Hogging or Finishing, End Mills Are Up to the Task - cemented carbide milling insert

 2024-07-25 14:03:27

Groove or other tool geometry that breaks chips into small fragments as they come off the workpiece. Designed to prevent chips from becoming so long that they are difficult to control, catch in turning parts and cause safety problems.

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.

The lower the lead angle, the thinner the chip and the smaller the force on the tool. To maintain the proper chip load, feed rates must be increased to compensate.

Various toolholder sizes are available for internal grooving with a minimum bore diameter (DMIN) of 8 mm (0.31") up to 24 mm (0.95"). Carbide shank toolholders are also available for shank diameters of 16 mm (0.63") and smaller for added tool rigidity during long-reach applications where vibration control is vital.

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 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.

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.

Depending on the material, the new grade and design support cutting depths ranging to 2.1 mm at 3-mm-per-tooth feeds, compared to 1.2-mm depths at 3-mm-per-tooth feeds for DAH 37 tools. Also notable is the fact that all DAH 62 tools use the same inserts; the case is the same with the DAH 37 tools. Common inserts for each series make tool management easier from a logistical standpoint, he notes.

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

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 revising part designs, investigate the 3D CAD, the 2D drawing and the part’s functional requirements to determine which details should be tightened up.

Engagement of a tool’s cutting edge with a workpiece generates a cutting force. Such a cutting force combines tangential, feed and radial forces, which can be measured by a dynamometer. Of the three cutting force components, tangential force is the greatest. Tangential force generates torque and accounts for more than 95 percent of the machining power. See dynamometer.

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.

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.

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

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

For any shop tasked with heavy hogging, chances are good that the go-to strategy involves taking a light cut at a heavy feed rate. The increasing popularity of this approach has been driven by the advent of roughing insert geometry that takes advantage of chip thinning to maximize both metal-removal rates and tool life.

The DAH 37 line includes round-shank and screw-on milling cutters in four diameters: 20, 25, 32 and 40 mm. The DAH 62 series expands that range with four interchangeable tool bodies offering cutting diameters of 63, 80, 100 and 125 mm. All holders feature inner cooling and TiN coating to protect against chip wash.

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.

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

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.

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.

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

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.

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

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

One such coating is among the features introduced with Horn’s DAH 62 line, which is designed for more aggressive cutting compared to the established DAH 37 series. While suitable for a range of materials and applications, the SC6A grade improves on the performance of the SA4B grade, particularly in cast materials, steels and nodular irons, he says. In addition, the DAH 62 series’ triple-edged inserts are twice as thick as those on DAH 37 cutters. They also offer a geometry that aids in directing chips away from the cutter body—a feature Mr. Farthing describes as “more of a chip former than a chip breaker.”

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

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

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.

These design features also contribute to the stability required to run at the parameters typically associated with high-feed cutting. The large edge radius, for example, adds strength by distributing cutting forces for more even tool wear. And, along with the low lead angle, it serves to direct machining forces axially up into the spindle rather than radially against the side of the tool. With a lower side load, the tool experiences less vibration and is less likely to pull out of the spindle, Mr. Farthing says. Beyond geometry, high-feed tools like the DAH series tend to use TiAlN-based chemical vapor deposition (CVD) coatings to disperse heat, aid chip evacuation and reduce built-up edge.

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.

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.

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

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

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.

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.

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

Tungaloy is expanding its SNG line of internal grooving tools to include GMR, a new insert geometry that enables effective chip control and evacuation in internal grooving applications.

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

Main body of a tool; the portion of a drill or similar end-held tool that fits into a collet, chuck or similar mounting device.

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.

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

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.

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

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

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

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

All inserts are designed to remove a certain size chip, a value commonly expressed as feed per tooth, Mr. Farthing explains. Mounted at a 90-degree lead angle, a straight insert at the properly calculated rpm will produce a chip that is theoretically the same thickness as the programmed feed per tooth. Reduce the lead angle, however, and the chip becomes thinner because the cut is spread over a wider portion of the edge. Arriving at optimal chip thickness requires increasing feed per tooth to compensate.

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

Machining grooves and shallow channels. Example: grooving ball-bearing raceways. Typically performed by tools that are capable of light cuts at high feed rates. Imparts high-quality finish.

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).

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.

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

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

Available in AH7025 covering various materials, including carbon and alloy steels, stainless steel, and heat-resistant alloys

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.

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.

Substances having metallic properties and being composed of two or more chemical elements of which at least one is a metal.

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.

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

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

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

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

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."

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.

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

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.

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.

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.

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.

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.

Secures a cutting tool during a machining operation. Basic types include block, cartridge, chuck, collet, fixed, modular, quick-change and rotating.

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.

Chip evacuation is a major issue with internal grooving. The GMR geometry addresses this by offering a 3D chipbreaker pressed in the cutting edge and optimized rake angle that removes the chip out of the hole and reduces cutting force. This minimizes the risk of chip re-cuts which can cause tool breakage, especially when machining small diameters. This provides improved cycle time and productivity.

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

High-feed inserts, such as those mounted on these DAH 62 series tools, are characterized by large, rounded cutting edges and extremely low lead angles.

Among the latest high-feed cutting innovations is the recently expanded DAH milling series from Horn USA (Franklin, Tennessee). Although the new DAH 62 series tools offer their own advantages, they also operate according to the same basic principles that govern virtually all high-feed offerings. During a recent conversation, Jason Farthing, responsible for technical sales and marketing, offered insights into some of the common design features that make high-feed tools so effective, as well as what makes Horn’s tools different.

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

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

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

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

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.

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?

Steel containing specified quantities of alloying elements (other than carbon and the commonly accepted amounts of manganese, sulfur and phosphorus) added to cause changes in the metal’s mechanical and/or physical properties. Principal alloying elements are nickel, chromium, molybdenum and silicon. Some grades of alloy steels contain one or more of these elements: vanadium, boron, lead and copper.

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!

High-feed inserts like the DAH series trigon cutters, which are mounted at lead angles ranging from 5 to 11 degrees, push this chip-thinning effect to the extreme. In fact, DAH inserts can run at four times the feed rate as a 45-degree-lead-angle tool while maintaining the same chip thickness, Mr. Farthing says. He adds that these and other high-feed inserts also have large, rounded edges that further contribute to chip thinning.

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.

Angle of inclination between the face of the cutting tool and the workpiece. If the face of the tool lies in a plane through the axis of the workpiece, the tool is said to have a neutral, or zero, rake. If the inclination of the tool face makes the cutting edge more acute than when the rake angle is zero, the rake is positive. If the inclination of the tool face makes the cutting edge less acute or more blunt than when the rake angle is zero, the rake is negative.

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.

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

An examination of Horn’s recently expanded DAH series sheds light on the design features that make high-feed milling inserts effective. These particular tools also offer their own advantages.

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.

Whether Hogging or Finishing, End Mills Are Up to the Task - cemented carbide milling insert

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