Fall 2015 Tool Catalog - miniature carbide end mills

Carbide insert and cutting tool manufacturer Horn reports that an application at Jörg Bamann Mechanische Werkstatt – a job shop in Geretsried, Germany – is demonstrating that a Horn DAH high-feed, indexable-insert milling cutter in a B-axis lathe is able to helically interpolate a circular groove into a round steel workpiece 14 times faster than a toroidal mill.

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Next, the subcontractor tried replacing the turning tool with a conventional, 5-flute, toroidal milling cutter with indexable inserts in the B-axis tool spindle of a DMG Mori CTX 800 TC turning-milling centre. The roughing process was faster than axial turning but resulted in vibration and a high level of noise. Furthermore, the machining time was still too long for Mr Bamann. About 100 minutes were needed to produce the groove and each cutter was able to complete only 30 components before the inserts needed to be changed, so further process optimisation was called for.

Brake pads designed specifically for carbon rims are constructed to help control the amount of heat build up by sucking it away from the rim. It's important to use your brakes properly though to stop the rims heating up. Dragging your brakes on long descents is to be avoided.

But his favourite rides are multiday bikepacking trips, with all the huge amount of cycling tech and long days spent exploring new roads and trails - as well as histories and cultures. Most recently, he’s spent two weeks riding from Budapest into the mountains of Slovakia.

SwissStop's nomenclature for their pads takes a second to get your head round, but it makes sense once you know it.

Carbon-specific brake pads shouldn’t be used on aluminium rims because they are quite soft and will wear quickly. Also, if the pads are used on aluminium rims, little bits of metal from the braking track will embed themselves in the pads. If the pads are then used on carbon rims, the metal shards will abrade the carbon and damage the rims.

These pads, designed for "extreme all weather conditions", have something of a cult following for how well they perform in the wet. The soft compound is super grippy, although that does mean they wear faster than other pads.

These deliver the strong and consistent stopping power you would expect from top-flight Campagnolo pads. If you're riding vintage Campy rim brakes you'll need to look elsewhere however as these are only compatible with calipers produced from the year 2000 onwards.

If your bike has disc brakes however, you need to read our guide to the best brake pads for road and gravel bikes.

Carbide insert and cutting tool manufacturer Horn reports that an application at Jörg Bamann Mechanische Werkstatt – a job shop in Geretsried, Germany – is demonstrating that a Horn DAH high-feed, indexable-insert milling cutter in a B-axis lathe is able to helically interpolate a circular groove into a round steel workpiece 14 times faster than a toroidal mill. The 42CrMo4 (1.7225) alloy steel billet, quenched and tempered to 1,000N/mm², requires a 40mm wide groove having a 240mm outside diameter and a depth of just less than 90mm to be rough-machined. The component is a key part of a hydraulic rotator, used in the construction and forestry industries for rotating attachments carried by excavators. Seeking to optimise the groove machining process, owner Jörg Bamann approached Horn application engineer Korbinian Niedermeier, who recommended a high-feed milling solution. The subcontractor has been using Horn products for two decades, so knows the supplier well. Jörg Bamann (right) with Horn application engineer Korbinian Niedermeier Mr Bamaan says: “Before switching to milling, we tried to produce the recess in the component by axial turning, but it didn’t prove to be viable. We tried tool solutions from various manufacturers, but none of them had the technical capabilities we needed. Turning resulted in long chips and, due to the large groove depth, caused vibration that negatively affected the life of the inserts.” Next, the subcontractor tried replacing the turning tool with a conventional, 5-flute, toroidal milling cutter with indexable inserts in the B-axis tool spindle of a DMG Mori CTX 800 TC turning-milling centre. The roughing process was faster than axial turning but resulted in vibration and a high level of noise. Furthermore, the machining time was still too long for Mr Bamann. About 100 minutes were needed to produce the groove and each cutter was able to complete only 30 components before the inserts needed to be changed, so further process optimisation was called for. Mr Niedermeier proposed a 40mm diameter, high-feed DAH mill with five triple-edged inserts. At a cutting speed (vc) of 150m/minute, the tool is helically interpolated into the rotating workpiece with a continuous infeed depth (ap) of 1mm and 0.8mm feed per tooth (fz). The new machining time for the recess is now just seven minutes per component, more than 14 times faster, and the life of the indexable inserts has increased threefold to 90 components per edge. Mr Bamann affirms: “We are very happy with the result. Using the high-feed milling cutter has reduced the cycle time considerably and the load on the machine has also decreased, as cutting pressure and vibration are lower. There is still more potential for machining improvement.” Established in 1964 and now in its second generation of ownership, Jörg Bamann Mechanische Werkstatt CNC mills and turns parts for customers in a variety of industries in batch sizes ranging from one-offs to series production. The company's many years of experience in processing steels including stainless, aluminium alloys, non-ferrous metals, titanium and plastics are testament to its expertise and versatility. The use of modern CAD/CAM systems enables components to be machined quickly and cost-effectively to meet customer requirements. Horn Cutting Toolswww.phorn.co.uk

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If the name has “flash” in it, the pad is good for SRAM/Shimano, if it has “race” instead then the pad is suitable for Campagnolo. “Pro” means that the pad is thicker for a longer service life. Alternatively, there is “evo” which is good if you have particularly wide rims which can only really accept pads once they are half worn.

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This is one of the more economical ways to get Dura-Ace components on your bike. If you are going to have top-of-the-range parts anywhere on your bike, the part that controls your speed is probably the best place for it.

These are versatile pads that are designed to offer powerful and consistent braking in both the dry and the wet - although according to Shimano's own characteristics graph, there is a marked difference between performance in the dry (scored a 5)  and in the wet (scored a 2). Durability is good and as brake pads go they are easy to fit and pretty silent in all but the wettest conditions.

A softer compound will be more grippy and offer better braking - especially in the wet. However, because the compound is softer, it will wear faster than a harder compound. On the bright side, a soft compound is easier on the rims, meaning they’ll last longer before you have to replace them.

The latest Iscar LogiQuick campaign has unveiled a diverse range of new cutting tools, effectively replenishing the company's portfolio.

A cartridge system is stiffer because the brake shoe provides extra support for the pad, making the brakes more powerful and responsive. They have the added benefit that when it comes to changing the pads, you can just pop the old pads out and slide the new ones in. You don’t need to readjust the brake position. They're the best choice for serious riding.

The 42CrMo4 (1.7225) alloy steel billet, quenched and tempered to 1,000N/mm², requires a 40mm wide groove having a 240mm outside diameter and a depth of just less than 90mm to be rough-machined. The component is a key part of a hydraulic rotator, used in the construction and forestry industries for rotating attachments carried by excavators.

For alloy rims, you then have the choice of the “Original Black” compound or “BXP”. The Original Black is recommended for general use and performs better in dry conditions. If you're after a SwissStop pad for wet weather, then its BXP compound is what you'll need.

Established in 1964 and now in its second generation of ownership, Jörg Bamann Mechanische Werkstatt CNC mills and turns parts for customers in a variety of industries in batch sizes ranging from one-offs to series production.

If your road bike has caliper rim brakes, you'll want to fit the best rim brake pads to up your stopping power.

Although the Black Prince compound might not induce the same stomach-flipping raw deceleration as the Yellow King, it does offer superior modulation. This allows you to really get the most out of your brakes.

Created to work in both wet and dry conditions, the Dura-Ace pads are also compatible with SRAM road calipers.

The company's many years of experience in processing steels including stainless, aluminium alloys, non-ferrous metals, titanium and plastics are testament to its expertise and versatility. The use of modern CAD/CAM systems enables components to be machined quickly and cost-effectively to meet customer requirements.

We’ve rounded up the best rim brake pads for road bikes, if you're looking for better braking performance no matter whether it’s wet or dry?

Arguably, this is not much of a problem. In being quite soft they are easy on the braking track, meaning that you’ll get more life out of your rims. Swapping pads a little more frequently is cheaper - and a lot easier - than rebuilding your wheels.

Hundreds of British manufacturing companies opened their doors in a UK-wide open house today as part of National Manufacturing Day, giving their local communities the chance to see the highly paid careers and jobs on offer in our exciting and diverse sector.

The HyproJET X6 from Ceratizit is based on an improved and patented design which makes is possible to increase cutting performance, leading and lifetime.

As a USA brand, they can be a little difficult to get hold of if you're in the  UK, but a definitely worth the extra effort if your looking for a pad that can help your braking performance in less than ideal weather conditions.

Coalville, Leicestershire-based CMS Cepcor is a leading supplier of aftermarket crusher spares, manganese-steel wear liners and other equipment for the mining, aggregate production and associated industries worldwide.

Mr Niedermeier proposed a 40mm diameter, high-feed DAH mill with five triple-edged inserts. At a cutting speed (vc) of 150m/minute, the tool is helically interpolated into the rotating workpiece with a continuous infeed depth (ap) of 1mm and 0.8mm feed per tooth (fz). The new machining time for the recess is now just seven minutes per component, more than 14 times faster, and the life of the indexable inserts has increased threefold to 90 components per edge.

The R4 Dura featured a plow-tip design which helps remove dirt and water before the pad touches the rim. It makes these a good choice if you use your carbon rims year-round or live in a region where rain is often on the horizon.

A South West-based engineering team is aiming to transform the large-format additive manufacturing sector with the launch of its latest product.

The latest Iscar LogiQuick campaign has unveiled a diverse range of new cutting tools, effectively replenishing the company's portfolio.

A super soft compound might work well in the wet, but it can be a little too grabby in the dry. Using a mixed compound, or one that is designed for the dry, will improve the brake’s modulation. It's therefore easier to control the amount of braking power you’re exerting, so you don’t accidentally lock up a wheel.

Since then, he’s earnt his 2ⁿᵈ cat racing licence in his first season racing as a third, completed the South Downs Double in under 20 hours and Everested in under 12.

Whether you’re slowing into a corner or pulling up at a junction, the consequences of cycling with an unreliable set of bike brakes and pads don’t bare thinking about. Better brake pads are a surprisingly cheap upgrade, especially for something that so dramatically affects both your safety and your performance.

Carbon rims and aluminium alloy rims require different brake pads. For carbon rims especially, it is very important that the correct pads are used.

You’re able to get right up to (but not exceed) the limits of your tires’ grip - that precise point before the wheels lock up and the tires start to skid - where you’re exerting the maximum braking force possible for the conditions.

As with the alloy pads, the “flash” means these are for SRAM/Shimano and “pro” means the pad is thick. For carbon rims, there are two compounds to choose from, “Black Prince” and “Yellow King”. Yellow King provides a little more in terms of absolute stopping power - but what is power without control?

The Dura 2 is a thicker version of this pad, so even considering the wear rate, you won’t actually have to replace them that often. Other Dura compounds include black for dry riding and triple for "superb braking in all conditions".

After winning the 2019 National Single-Speed Cross-Country Mountain Biking Championships and claiming the plushie unicorn (true story), Stefan swapped the flat-bars for drop-bars and has never looked back.

A high-quality set of brake pads, with a compound specifically formulated for the conditions, can have a transformative effect on your stopping distance.

Designed to work across conditions, these are solid all rounder, which should deliver assured braking performance in a range of conditions. However, as you might expect Shimano's characteristics chart shows that they do perform slightly better in the dry compared to the wet.

MSC Industrial Supply Co. UK (MSC) is celebrating a successful season after sponsoring two local youth football teams during the 2023/2024 campaign.

The calipers, cable housing, and brake levers all have a role in determining how a braking system performs but it is the pads that have the greatest single effect. For this guide we've split the pads into two sections: alloy rims and carbon rims;

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Mr Bamann affirms: “We are very happy with the result. Using the high-feed milling cutter has reduced the cycle time considerably and the load on the machine has also decreased, as cutting pressure and vibration are lower. There is still more potential for machining improvement.”

The HyproJET X6 from Ceratizit is based on an improved and patented design which makes is possible to increase cutting performance, leading and lifetime.

Perhaps surprisingly Campagnolo also produce a SRAM/Shimano version of these pads as well - so that those on the dark side can enjoy superb braking on carbon rims as well.

The fact that the Dura-Ace pads are used widely by the top cycling teams should speak to their quality, even if they are supplied for free!

MSC Industrial Supply Co. UK (MSC) is celebrating a successful season after sponsoring two local youth football teams during the 2023/2024 campaign.

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Some brake pads come as a single brake block, whereas with others the brake pad functions as a cartridge that is inserted into a brake shoe.

Seeking to optimise the groove machining process, owner Jörg Bamann approached Horn application engineer Korbinian Niedermeier, who recommended a high-feed milling solution. The subcontractor has been using Horn products for two decades, so knows the supplier well.

Mr Bamaan says: “Before switching to milling, we tried to produce the recess in the component by axial turning, but it didn’t prove to be viable. We tried tool solutions from various manufacturers, but none of them had the technical capabilities we needed. Turning resulted in long chips and, due to the large groove depth, caused vibration that negatively affected the life of the inserts.”

Carbon isn’t as good as aluminium at conducting heat, meaning that carbon rims have a greater tendency to heat up. If the rims get too hot, you risk starting to melt the resin that holds the carbon fibres together and causing your inner tubes to pop, or even a failure of the rim itself, although modern carbon rims usually use high iTg resins to make them more resistant to heat build-up.

Featuring a design that removes dirt and water before the pad hits the rim, these are good for when the weather turns bad.

One-piece pads are cheaper to manufacture and so are often specced on lower value bikes or bikes that are trying hard to come in below a certain price point. The brakes tend to feel a little mushier and the pads tend to be made from lower performing compounds to keep the costs down.

We’ve split this guide into best brake pads for alloy rims and best brake pads for carbon rims to make it easier to find the brake pads you need. Some manufacturers require you to use only certain makes of brake pad on their rims. If you use a pad that is not recommended, you risk voiding your warranty, so it is best to double check before using a different set of pads.