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.

Improving a cutting geometry is an important direction in the development of cutting tools. Cutting geometry is a subject of theoretical and experimental researches, and advances in science and technology have brought a new powerful instrument to aid in tool design: 3D modelling of chip formation. Iscar’s R&D team actively uses modelling to find optimal cutting geometries and form the rake face of indexable inserts and exchangeable heads.

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.

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.

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

With Tungaloy’s cutter and square inserts, Progressive Metal machines its 4130 gates at 500 sfm and 0.075-inch depth of cut, and between 0.012 and 0.018 inch per tooth depending on how much material Johnson can clamp. The DoTriple-Mill reduced the process’ original 40-minute cycle time by between 30% and 40%, Johnson says, with further optimizations saving another 10%. These productivity improvements and the elimination of job-specific tooling by switching to the DoTriple-Mill ultimately halved the company’s tooling costs for the job.

Many materials used for manufacturing aircraft components have poor machinability. Titanium, high temperature superalloys (HTSA) and composites are difficult-to-cut materials. In order to increase output rate and improve productivity, aerospace component manufacturers must use machine tools capable of implementing advanced machining operations. In such conditions, the role of cutting tools are significantly increased; however, they can represent the weakest link in the whole manufacturing system due to their low durability as a system element, which can decrease productivity. Aerospace customers expect higher levels of performance and reliability from cutting tools and manufacturers have been both challenged and inspired, in terms of developing and integrating sometimes unconventional solutions into their products, to meet these expectations.

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

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.

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.

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!

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).

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.

Iscar’s modular drills for multi-spindle and Swiss-type machines combine the SUMOCHAM design with a FLEXFIT threaded connection [Fig3]A further example of simplified customisation can be found in Iscar’s modular drills for multi-spindle and Swiss-type machines. The drills combine the SUMOCHAM design with a FLEXFIT threaded connection (Fig. 3). Multi-spindle and Swiss-type machines typically have a limited space for tooling, which means that the tools in operation need to be as short as possible to avoid collisions and facilitate easy set up. A wide range of FLEXFIT threaded adaptors and flatted shanks has been designed precisely to fit the drills and maximally shorten an overhang.

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

Johnson contacted Tungaloy sales engineer Greg Davis, whom Johnson knew from his previous position, and obtained a recommendation for the DoTriple-Mill.

The NeoMill-Alu-QBig indexable insert milling cutter from Mapal stands for top performance in high-volume milling of aluminium. The tool manufacturer thus offers a very economical solution for use on high-performance machines, such as those found primarily in the aerospace industry.

To achieve these goals, the industry must constantly improve the design of aircraft engines and airframe structural elements, to increase the protection of the aircraft from the damaging action of such dangerous factors as lightning and icing. This in turn has resulted in a series of industry demands, including the introduction of engineering materials that require new production technologies, developing appropriate machinery and cutting tools. The aircraft manufacturer has to deal with complex parts, which are produced from various materials with the use of different machining strategies. This is why the aerospace industry is considered as a powerful and leading force for progress in cutting tool development.

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

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.

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

Woodgate Business Park Clapgate Lane Bartley Green B32 3DE UNITED KINGDOM 0121 244 3061

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.

Walter has now launched its new X·treme Evo Plus drill from the DC180 Supreme product family that is now available up to 8XD for the first time.

ANT Industries, a leading manufacturer of aero engine and gas turbine components in Atherstone, Warwickshire, has announced a significant milestone in its commitment to quality and excellence.

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

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.

In hole making, applying modelling to the design process significantly contributed to creating a chip splitting geometry of SUMOCHAM exchangeable carbide heads for drilling holes with depth up to 12-hole diameters in hard-to-cut austenitic and duplex stainless steel.

When it comes to workholding, shops can choose from options that can provide flexibility, help increase throughput and enable five-axis machining.

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.

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

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

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.

Connect with the manufacturing community and supply-chain across 3 days at the UK’s leading annual industrial event.

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.

According to Johnson, the DoTriple-Mill alone cut cycle time by between 30% and 40% — with further optimizations saving another 10%.

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

Most cutting tools continue to be manufactured from cemented carbide. Over recent years, Iscar has introduced several carbide grades designed specifically for aerospace materials, including IC 5820. The grade combines the advantages of a new submicron substrate, a progressive hard CVD coating, and a post-coating treatment to substantially increase impact strength and heat resistance. The inserts from this grade are intended mostly for milling titanium. Pinpointed wet cooling and especially high-pressure coolant (HPC) significantly improve grade performance.

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.

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.

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

As for the rest of the machine shop staff, Johnson says adoption went smoothly, with their main question stemming from the cutter’s durability: “When is it going to wear out?”

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

For turning applications, the company expanded its line of indexable SiAlON inserts for machining HTSA materials. The new products (Fig. 1) have already proved their effectiveness in turning aero engine parts from super alloys such as Waspaloy and different Inconel and Rene grades. In contrast to other silicon nitride ceramics, SiAlON possesses higher oxidation resistance but less toughness. Therefore, a key of a SiAlON insert reliability is additional edge preparation. Iscar's new ‘TE’ edge geometry has been developed to increase tool life in heavy load conditions during rough operations and interrupted cuts.

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

Iscar has expanded its family of 90° indexable milling cutters by introducing new tools carrying large-size inserts [Fig4]In hole making, the company developed new inserts for drilling aluminium with indexable drills from the DR-TWIST drilling tool range. The inserts are peripherally ground and feature sharp cutting edges and polished rake face for light cut, preventing adhesion.

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

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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

Iscar's cutting tool program for the aerospace sector is based on several principles: the complex needs of this industry, taking into consideration trends in metalworking, and the drive to strengthen partnerships with tool consumers. Iscar believes that such a tri-pronged approach ensures the successful realisation of innovative ideas for efficient machining of the difficult-to-cut materials that characterise this challenging and dynamic field.

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.

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

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

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

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?

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."

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A job shop might have an amount of money tied up in tooling equal to a significant share of its investment in CNC machines. Here is how one shop owner thinks about tool management.

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.

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

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.

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

Although machining aluminium might appear to be an extremely simple process, effective cutting of aluminium actually represents a whole field of technology with its own laws and challenges.

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

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 cutter’s ability to use round, square and octagonal inserts (the “Triple” of the mill’s name) in the same pocket was a key selling point, although Progressive uses only round and square inserts. As Davis puts it, “[the DoTriple-Mill] may not necessarily be the ideal cutter for any one application, but it is a good all-around cutter that will handle different materials just by changing the insert geometry.” For example, square inserts maximize metal removal for 4130 applications, while round inserts resist wear and support longer tool life in Inconel applications.

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

Tungaloy’s DoTriple-Mill includes slots for cutting inserts with round, square and octagonal geometries. Progressive Metal uses square inserts on its 4130 heat-treated steel pieces and round inserts on its Inconel 718 pieces.

If you find this article informative, consider subscribing digitally to Aerospace Manufacturing for free. Keep up to date with the latest industry news in your inbox as well as being the first to receive our magazine in digital form.

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

Tooling manufacturer, Horn has introduced a new carbide insert grade, SG66, for turning components from steel that has been case hardened to 58 HRC.

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.

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.

At just 28 years old, Amy Skrzypczak is already logging her ninth year as a CNC machinist. While during high school Skrzypczak may not have guessed that she’d soon be running an electrical discharge machining (EDM) department, after attending her local community college she found a home among the “misfits” at Westminster Tool. Today, she oversees the company’s wire EDM operations and feels grateful to have avoided more well-worn career paths.

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

Iscar developed the MULTI-MASTER and SUMOCHAM families of rotating tools with exchangeable heads and different body configurations to ensure various tool assembly options that simplify customisation and decrease the need for costly tailormade products.

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

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

The DoTriple-Mill’s negative rake additionally helps hold the valves’ shape, reducing the amount of finish grinding they need. Reprogramming was also simple, with Johnson adjusting Progressive Metal’s machine programs in around 15 minutes.

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.

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.

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

Johnson’s initial improvement strategy focused on one of Progressive Metal’s staple jobs: machining the internal components of gate valves. The company’s customers primarily use these valves to control the flow of liquids and mud at fracking sites. Progressive Metal makes five different sizes of this part with holes ranging from two to seven inches in diameter, as well as variants for different levels of PSI. Depending on the build requirements, these valves can be 4130 heat-treated steel or Inconel 718.

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

Progressive Metal offers gate valves in five sizes, with additional variants to account for different PSI needs. Cycle times plummeted from 40 minutes to nearly half that with the introduction of Tungaloy’s DoTriple-Mill and cutting inserts. Photos courtesy of Progressive Metal Service.

The F3S chipformer has been designed for finish turning high temperature nickel-based alloys and exotic materials [Fig2]The F3S chipformer for the most popular ISO inserts, such as CNMG, WNMG and SNMG, was designed specifically for finish turning high temperature nickel-based alloys and exotic materials (Fig. 2). It ensures a smooth and easy cut with notable chip breaking results. The remarkable working capability of the designed cutting geometry is a direct result of chip flow modelling.

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

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

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.

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.

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

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."

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

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.

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.

Aerospace products can vary immensely in material, dimensions, shape, complexity, and more. To make such a diverse range of products, the product manufacturer needs dozens of machine tools and technological processes. Not every standard cutting tool is optimal for performing certain machining operations with maximum productivity and, consequently, the aerospace industry is a leading consumer of customised tools.

The need to increase productivity and boost metal removal rates for milling aluminium workpieces, especially large parts of aerospace structural components, has led machine tool builders to develop milling machines with a powerful main drive - up to 150kW - with high spindle speeds of up to 33,000rpm. To meet this demand, Iscar has expanded its family of 90° indexable milling cutters by introducing new tools carrying large-size inserts that enable up to 22mm depth of cut (Fig. 4). The tools have been designed to eliminate insert radial displacement, which might occur due to high centrifugal forces during very high rotational speed. This concept facilitates reliable milling in a rotational speed range of up to 31,000rpm.

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

Student-run businesses focused on technical training for the trades are taking root across the U.S. Can we — should we — leverage their regional successes into a nationwide platform?

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

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.

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

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

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

Responding to demands from the aerospace sector, the company also expanded the MULTI-MASTER family by introducing a new thread connection to increase the diameter range for the exchangeable endmill heads to 32mm.

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.

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The America’s Cutting Edge (ACE) program is addressing the current shortage in trained and available workers by offering no-cost online and in-person training opportunities in CNC machining and metrology.

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.

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

Progressive Metal Service previously used a 5-inch-diameter, 45-degree-lead face mill on its gate valves, but between high cutting forces and a process that only gripped 0.1 inch of material, this setup could lift the part out of the vise and damage part, insert and cutter. The close-pitch version of the DoTriple-Mill and the new inserts have a starker, double-negative rake angle that leverages cutting forces to push the part into the vise, better securing it and enabling Progressive Metal’s machinists to increase both feed rates (unusual for a double-negative rake) and depths of cut.

The aerospace industry features continuous efforts aimed at improving aircraft component manufacturing efficiency, increasing flight safety, and reducing potential environmental damage.

The transition into Swiss-type machining at Deking Screw Products required more than just a shift in production operations. It required a new mindset and a new way of running the family-owned business. Hardest of all, it required that one generation let go, and allow a new one to step in.

New capabilities bring new opportunities, but sometimes the greatest opportunities come from improving existing processes. For Progressive Metal Service, a coating; assembly; salt bath nitriding; and turnkey manufacturing company, new tooling for a routine face milling application led to significant cycle time and tooling cost reductions. This opportunity came about after machining general manager Mike Johnson joined the company in December 2021 and began identifying applications with room for improvement.

Progressive Metal’s valve gates progress through five process stages: raw material; facing and profiling; t-slotting and chamfering; grinding; and nitride coating.

Ceramics, another tool material, possess considerably higher hot hardness and chemical inertness than cemented carbides. This means that ceramics ensure much greater cutting speeds and eliminate diffusion wear. One of the last Iscar's developments, a family of solid ceramic endmills, is intended for machining HTSA. These endmills are made from SiAlON - a type of silicon-nitride-based ceramic comprising silicon, aluminium, oxygen and nitrogen. When compared with solid carbide tools, the endmills enable an increase in cutting speed of up to 50 times, which can drastically save machining hours.

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

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.

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.

Roughing operations can push a CNC spindle to its limits. Understanding how to interpret the horsepower chart can keep these operations within safe limits.

A customer producing titanium parts might be interested in solutions comprising indexable shell mills and arbors from the standard line; while another customer producing similar parts might prefer special milling cutters with an integral body, for direct mounting in a machine spindle.

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

The aerospace industry features continuous efforts aimed at improving aircraft component manufacturing efficiency, increasing flight safety, and reducing potential environmental damage. To achieve these goals, the industry must constantly improve the design of aircraft engines and airframe structural elements, to increase the protection of the aircraft from the damaging action of such dangerous factors as lightning and icing. This in turn has resulted in a series of industry demands, including the introduction of engineering materials that require new production technologies, developing appropriate machinery and cutting tools. The aircraft manufacturer has to deal with complex parts, which are produced from various materials with the use of different machining strategies. This is why the aerospace industry is considered as a powerful and leading force for progress in cutting tool development. Many materials used for manufacturing aircraft components have poor machinability. Titanium, high temperature superalloys (HTSA) and composites are difficult-to-cut materials. In order to increase output rate and improve productivity, aerospace component manufacturers must use machine tools capable of implementing advanced machining operations. In such conditions, the role of cutting tools are significantly increased; however, they can represent the weakest link in the whole manufacturing system due to their low durability as a system element, which can decrease productivity. Aerospace customers expect higher levels of performance and reliability from cutting tools and manufacturers have been both challenged and inspired, in terms of developing and integrating sometimes unconventional solutions into their products, to meet these expectations. Basic materials Most cutting tools continue to be manufactured from cemented carbide. Over recent years, Iscar has introduced several carbide grades designed specifically for aerospace materials, including IC 5820. The grade combines the advantages of a new submicron substrate, a progressive hard CVD coating, and a post-coating treatment to substantially increase impact strength and heat resistance. The inserts from this grade are intended mostly for milling titanium. Pinpointed wet cooling and especially high-pressure coolant (HPC) significantly improve grade performance. Ceramics, another tool material, possess considerably higher hot hardness and chemical inertness than cemented carbides. This means that ceramics ensure much greater cutting speeds and eliminate diffusion wear. One of the last Iscar's developments, a family of solid ceramic endmills, is intended for machining HTSA. These endmills are made from SiAlON - a type of silicon-nitride-based ceramic comprising silicon, aluminium, oxygen and nitrogen. When compared with solid carbide tools, the endmills enable an increase in cutting speed of up to 50 times, which can drastically save machining hours. For turning applications, the company expanded its line of indexable SiAlON inserts for machining HTSA materials. The new products (Fig. 1) have already proved their effectiveness in turning aero engine parts from super alloys such as Waspaloy and different Inconel and Rene grades. In contrast to other silicon nitride ceramics, SiAlON possesses higher oxidation resistance but less toughness. Therefore, a key of a SiAlON insert reliability is additional edge preparation. Iscar's new ‘TE’ edge geometry has been developed to increase tool life in heavy load conditions during rough operations and interrupted cuts. Advanced geometry Improving a cutting geometry is an important direction in the development of cutting tools. Cutting geometry is a subject of theoretical and experimental researches, and advances in science and technology have brought a new powerful instrument to aid in tool design: 3D modelling of chip formation. Iscar’s R&D team actively uses modelling to find optimal cutting geometries and form the rake face of indexable inserts and exchangeable heads. The F3S chipformer has been designed for finish turning high temperature nickel-based alloys and exotic materials [Fig2]The F3S chipformer for the most popular ISO inserts, such as CNMG, WNMG and SNMG, was designed specifically for finish turning high temperature nickel-based alloys and exotic materials (Fig. 2). It ensures a smooth and easy cut with notable chip breaking results. The remarkable working capability of the designed cutting geometry is a direct result of chip flow modelling. In hole making, applying modelling to the design process significantly contributed to creating a chip splitting geometry of SUMOCHAM exchangeable carbide heads for drilling holes with depth up to 12-hole diameters in hard-to-cut austenitic and duplex stainless steel. Flexible customisation Aerospace products can vary immensely in material, dimensions, shape, complexity, and more. To make such a diverse range of products, the product manufacturer needs dozens of machine tools and technological processes. Not every standard cutting tool is optimal for performing certain machining operations with maximum productivity and, consequently, the aerospace industry is a leading consumer of customised tools. A customer producing titanium parts might be interested in solutions comprising indexable shell mills and arbors from the standard line; while another customer producing similar parts might prefer special milling cutters with an integral body, for direct mounting in a machine spindle. Iscar developed the MULTI-MASTER and SUMOCHAM families of rotating tools with exchangeable heads and different body configurations to ensure various tool assembly options that simplify customisation and decrease the need for costly tailormade products. Iscar’s modular drills for multi-spindle and Swiss-type machines combine the SUMOCHAM design with a FLEXFIT threaded connection [Fig3]A further example of simplified customisation can be found in Iscar’s modular drills for multi-spindle and Swiss-type machines. The drills combine the SUMOCHAM design with a FLEXFIT threaded connection (Fig. 3). Multi-spindle and Swiss-type machines typically have a limited space for tooling, which means that the tools in operation need to be as short as possible to avoid collisions and facilitate easy set up. A wide range of FLEXFIT threaded adaptors and flatted shanks has been designed precisely to fit the drills and maximally shorten an overhang. Responding to demands from the aerospace sector, the company also expanded the MULTI-MASTER family by introducing a new thread connection to increase the diameter range for the exchangeable endmill heads to 32mm. Aluminium machining Although machining aluminium might appear to be an extremely simple process, effective cutting of aluminium actually represents a whole field of technology with its own laws and challenges. The need to increase productivity and boost metal removal rates for milling aluminium workpieces, especially large parts of aerospace structural components, has led machine tool builders to develop milling machines with a powerful main drive - up to 150kW - with high spindle speeds of up to 33,000rpm. To meet this demand, Iscar has expanded its family of 90° indexable milling cutters by introducing new tools carrying large-size inserts that enable up to 22mm depth of cut (Fig. 4). The tools have been designed to eliminate insert radial displacement, which might occur due to high centrifugal forces during very high rotational speed. This concept facilitates reliable milling in a rotational speed range of up to 31,000rpm. Iscar has expanded its family of 90° indexable milling cutters by introducing new tools carrying large-size inserts [Fig4]In hole making, the company developed new inserts for drilling aluminium with indexable drills from the DR-TWIST drilling tool range. The inserts are peripherally ground and feature sharp cutting edges and polished rake face for light cut, preventing adhesion. Iscar's cutting tool program for the aerospace sector is based on several principles: the complex needs of this industry, taking into consideration trends in metalworking, and the drive to strengthen partnerships with tool consumers. Iscar believes that such a tri-pronged approach ensures the successful realisation of innovative ideas for efficient machining of the difficult-to-cut materials that characterise this challenging and dynamic field. www.iscar.co.uk

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

Adopting a mill with a double-negative rake and pockets compatible with multiple insert geometries enabled Progressive Metal Service to increase feed and lower scrap rates for a valve.

The Diatool Top Speed Disc features a solid reamer body with multiple connections to produce tolerance stack up.

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.

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.

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.

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.

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

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.

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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.

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.

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