Gühring has launched a new range of milling cutters especially for mould

 2024-07-01 14:51:20

making - guhring solid carbide end mills

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.

“As much as our customers want it to be a finisher, a drill is still a roughing tool,” says Salvatore DeLuca, product manager at Allied Machine and Engineering. “It’s always going to cut slightly oversized.”

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.

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.

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

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.

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.

Water-soluble coolants are most common for general-purpose applications because they remove heat well. That said, semi-synthetic or fully oil-based formulations can be a better choice to improve lubricity and ensure short, segmented chips in certain cases. Although tools may wear more quickly and parameters may need to be less aggressive than with a water-based coolant, an insert coating that improves heat resistance might help compensate. It all depends on the application.

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

Walter’s multi-row threadmills are normally viewed as problem solvers with tapered threads or fewer teeth to reduce chatter, according to Pollock. “But the Walter multi-row threadmills are designed so that the lower cutting forces allow feeding the tool faster and matching or reducing the cycle time compared to cut taps,” he said. “We have two different styles: a solid-carbide version for threads less than 7/8” (TC620) and an indexable version for threads greater than 7/8” (T271x). These tools allow the user to gain all the advantages of thread milling—such as lower cost per thread and longer tool life—without sacrificing the cycle time.”

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

Pecking might be the only option if there is no time for new tools or other process adjustments. However, the result is always slower drilling. In addition, retracting the tool mid-cut can leave partially formed, undetached chips inside the hole. Carbide is wear-resistant but relatively brittle, a characteristic that can make inserts prone to premature or even catastrophic failure upon repeated contact with such a jagged, inconsistent surface. Even if inserts are not compromised, the workpiece could be. As mentioned above, most drills cut slightly oversized. “Maybe it’s only by a few thou (1 “thou” = 0.001 inch), but on some jobs, there might still be a risk of scarring the inside of the hole or cutting an oversized hole,” he explains.

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

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

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

Nonetheless, he says it is easy to understand high expectations for replaceable-tip drills like those manufactured by Allied, a specialist in holemaking tools. In the right application, the latest offerings can leave holes straight and smooth enough to make dedicated finishing tools unnecessary.

“One of the most underestimated inputs in any machining process, even beyond drilling, is the coolant.”

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!

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

“Approaching a pre-existing hole cautiously helps avoid scarring or damage,” Mr. DeLuca says about these recommendations. “It allows the drill margins to engage with the material before you bring it up to speed. The hole begins to act like a bushing that keeps the drill centered and keeps parts and people safe.”

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.

According to Hudgins, troubleshooting threading problems often turns up one of several issues. “One of the biggest issues with threading can often be solved by changing the infeed method—the angle of entry into the thread,” he said. “One of the easiest but least recommended is the straight zero-degree infeed, where you are engaging both sides of the insert at once. A lot of heat is created and using a modified flank infeed instead reduces the amount of heat in the cut and the amount of pressure in the cut and also protects the trailing edge. Another issue is that the machine may not always be on centerline, a condition that is caused by machine crashes and that can be easily corrected. Modern CNC machines and Swiss machines have the ability to offset the Y axis, alleviating the machine off center problem.”

There is no room in a modern production environment for climbing into workzones to mount indicators, nor for holding pieces of paper in place for tool touch-offs.

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.

Allied’s T-A drills are available with 187 different combinations of standard insert geometries and coatings, and this is just one line of tools from one manufacturer. With so many application-specific choices available, strategies for insert drills that were once standard procedure might no longer apply.

According to Pollock, the Walter lineup of products consists of three tool categories. Supreme indicates the highest level of technology and performance available; Perform tools provide an economical solution with focused importance on price; and Advance indicates a product efficiently balanced between price and performance. The Advance product family makes tool selection simple due to the universal application, meaning it will work in most materials, from ISO P, M, K and S. “And being a high performer with a competitive price, it’s at a level that most of Walter’s customers are looking for,” said Pollock.

A different option for threadmaking, YG-1’s popular 60° helical flute TiAlN-coated unified and metric thread mills are available with or without cooling. The combination multifunction tools drill, thread mill and chamfer in one setup and are especially well suited for niche applications. “It takes the right application and the right circumstances for these tools to be effective,” said Ford. “In the thread mill line, YG-1 offers pipe threads, NPT, NPTF, NSP and NPSF, though not gas pipe threads in the U.S.”

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

At one customer’s facility, three of Allied Machine’s replaceable-tip, self-guided “Stealth” drills (so named for their quiet operation) are set up in the toolroom at the beginning of each shift. This process takes less than 10 minutes. In contrast, setting up three tools on the machining line could take as long as 30 minutes, amounting to 90 minutes of lost time over the course of three shifts. In a 24/7 production environment, that adds up to nearly 2,200 hours per year (a figure that does not account for machine downtime during tool changes). “A presetter is probably 5% of the cost of those lost hours,” Mr. DeLuca notes.

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.

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

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.

For thread milling, machines must have three-axis simultaneous interpolation. For this operation, Allied offers Insta-Code programming downloadable from its website. Entering machining conditions and the desired thread will generate a program. “Insta-Code has been very popular and is being used by us and by our customers, who can add it as an engineering staff resource.” Also available from Allied Machine’s website is a link to its Thread Mill Pocket Guide with comprehensive information about different threads and cutting conditions.

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.

In addition to saving time, making drill margins easier to find and measure prevents costly mistakes. “In my opinion, the ease of setup alone is worth the investment,” Mr. DeLuca says. “When you look at the reduction in setup cost and machine downtime due to incorrect setup measurements, it’s hard to imagine not having a presetter.”

To save critical machining time while producing high-quality internal threads in aluminum alloys, Emuge-Franken N.A., West Boylston, Mass., and Audi AG, Ingolstadt, Germany, worked on a new threading tool technology called Taptor that combines a twist drill with a tap.

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

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).

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.

In fact, most replaceable-tip drilling inserts feature self-centering tips with point angles shallower than 90 degrees. As a result, the insert can impact the hole’s major diameter before the self-centering point. “If you were to follow a standard spot drill with one of our tools, our drill will want to walk slightly, causing premature wear and potentially causing the tool to lead off,” Mr. DeLuca explains. “Using the same insert diameter and point angle ensures that the longer drill picks up perfectly where the spot drill left off.”

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

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.

Surface measurement is becoming increasingly important to ensure proper performance of a manufactured product. Advanced surface measurement tools are not only beneficial in the manufacturing industry but also have unconventional applications.

Not to be overlooked, said Burton, are infeed type and insert inclination. “There are three different types of infeed which can have a significant impact on the thread machining process, affecting chip control, insert wear, thread quality and tool life. The choice of infeed method is influenced by the machine tool, insert geometry, workpiece material and thread pitch.”

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.

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

cnSEE from All World Machinery Supply combines easy installation and monitoring across multiple machines.

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

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

Modified Flank Infeed: Most newer CNC machines can be programmed for modified flank infeed, which is used with C-geometry as the chip breaker won’t function with radial infeed. Axially directed cutting forces reduce the risk of vibrations and control chip direction. This is the first choice for most threading operations; the chip is similar to that in conventional turning, making it easier to form and guide.

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.

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

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

The deeper the hole, the longer the drill. The longer the drill (the greater the distance between the tool tip and the spindle nose), the greater the extent to which runout can impact results. In some deep-hole applications, the slightest wobble can wear tools prematurely and compromise both straightness and surface finish.

He added that threading and milling advances are spurred by improvements in the machines producing the parts. “For example, many of today’s machines are lighter and faster, as opposed to earlier units that relied on mass and weight to reduce vibration,” said Dei. “Also, we are seeing more multi-purpose machines that combine both milling and turning. It’s up to us as toolmakers to see the ‘big picture’ and respond accordingly.”

In addition to solid-carbide tools, Allied Machine offers AccuThread replaceable insert thread mills in two styles, bolt-in and pin, for flexibility in meeting the variety of threading applications found in job shops.

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.

YG-1 Tool Co., Vernon Hills, Illinois, offers a portfolio of taps that covers everything from the tool room to high-volume repetitive production, according to Mark Ford, YG-1’s director global product management–threading. “We divide our products into several different categories of metric and unified taps, including Combo Tap multipurpose taps with and without internal cooling,” said Ford. “Tools are designed around specific materials groups, including stainless steel, aluminum, high-temperature alloys and cast iron. Other tools are more application-specific, like pipe taps, roll form taps and thread inserts.”

A major advancement to Iscar’s thread turning capability is the JHP high-pressure coolant delivery system with retractable nozzle for easy insert change. “With JHP we are able to get the coolant right into the cutting zone. In the case of many threads, like a 60° V thread, the insert comes to a very small point, which is fragile and very accessible to heat. Putting the coolant right into the cutting zone improves tool life significantly as well as chip control,” said Hudgins. “When cutting stainless and high-temp materials, getting coolant right into the cutting zone with high-pressure coolant makes the chips a little more brittle. Even if you aren’t going to break threading chips into 6’s and 9’s like turning, you can curl them up and make it so they aren’t wrapping around the part or around the tooling.”

However, there is more to precise, efficient drilling than the tools themselves, particularly in holes with depth-to-diameter ratios of 9:1 or more. In a recent conversation, Mr. DeLuca outlined five recommendations for drilling deep with the company’s T-A system, a broad line of general-purpose, replaceable-tip drills designed to penetrate most steels, cast irons, high-temperature alloys and aluminum 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.

Walter, which carries a full line of products for tapping, thread forming and thread milling, has introduced a family of taps, TC117 and TC217, that is positioned in its Advance line for universal applications.

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

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.

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.

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

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.

“When you see pecking these days, it’s usually someone misapplying a tool or using the wrong tool entirely.”

Another outdated practice is the use of a 90-degree spot drill with a smaller diameter for the pilot hole. This makes sense intuitively, and, as is the case with pecking, can still be a useful rule of thumb for toolroom applications. After all, a smaller-diameter hole drilled slightly off-center is easier to correct than a larger one, while a sharp point angle helps the drill quickly and easily penetrate the part and settle into position. However, most CNC machine tools position precisely enough that the pilot drill can be the same diameter as the main drill. They are also powerful enough to drive duller points into virgin workpiece material.

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."

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

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.

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

Barring some form of X-ray vision, chip formation is the only way to judge a drill’s performance during the cut, while there is still time to act. Curlicue shapes (that is, “sixes” and “nines”) are ideal, while longer, stringier chips carry heat away from the cutting zone less efficiently. Color matters, too. As the cutting zone over heats, chips become progressively gray, black and blue. Discolored chips can indicate the need to reduce heat by slowing spindle rpm, while stringy chips might indicate the need to increase the feed rate to a point in which machined material breaks rather than peels.

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

Radial Infeed: Used by all manual machines and most canned CNC programs and the first choice for work hardening materials and suitable for fine pitches.

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

One non-negotiable factor is the use of through-coolant drills. Machine tools must also deliver sufficient coolant pressure. Small drills require significantly more pressure for chip evacuation to keep up with material removal because they must run at higher rpm to achieve the same surface speed as larger tools. “The greater the pressure, the faster the chips come out of the hole, and the faster you can spin the drill,” Mr. DeLuca says.

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.

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

Allied Machine supplies tools for complete holemaking, including roughing, reaming, threading and finishing holes for customers as diverse as mold and die and aerospace. “Thread milling allows our customers to use one thread mill to machine multiple diameters without having to stock a tap for each hole diameter,” said Ripple. “In addition, there is no removing a broken tap in a mold and die application where it is costly to scrap a high-value workpiece. Even the eye bolt that holds the die needs to be threaded. For those heat-resistant aerospace workpieces, thread milling produces less heat than other threading operations, which directly improves tool life.”

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

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.

“Changes in the marketplace have also impacted tooling development,” said Dei. “For example, the trend towards smaller, more complex parts has resulted in increased demand for tooling designed for Swiss-style applications. Several of our lines, including Swiss Line, Tiny Tools and Mini Tools, offer the Carmex ‘helical advantage’ in those 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.

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

Tool breakage and scrapping are constant threats to successful threading of high-value workpieces like molds and dies and high-temperature alloys for aerospace applications. For threading difficult-to-machine materials, thread milling produces a high-quality thread with less tool pressure and less heat, according to Justin Ripple, product manager, Allied Machine & Engineering, Dover, Ohio. It also allows deeper threads for these materials.

To maximize machining efficiency, Sandvik Coromant introduced the CoroThread 266 high-precision coolant solution with an iLock high-precision toolholder. “The CoroThread 266 is effective for all insert geometries, grades and thread profiles, and from low to high coolant pressures,” said Lewis. “The combination of over-coolant for chip formation and under-coolant for improved insert life produces higher product quality and machining efficiency as well as process security in all external thread turning applications.” CoroThread 288 delivers coolant pressure precisely to the cutting zone at more than 1,000 psi. “The iLock high-precision holder handles the extreme forces placed upon the insert, providing exceptional stability for ultimate accuracy, surface finish and product consistency,” Lewis said.

In this case, the Stealth Drill itself adds to the time-savings provided by offline presetting. This drill features an adjustable pin that moves the insert radially to mitigate the tolerance stack-up common to all replaceable-tip drills. As a result, dialing out runout no longer requires dismantling and cleaning the tool assembly, adjusting offsets, adding shims to tool turrets, or relying on experienced machinists to attempt an unorthodox solution.

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

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.

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

Burton described the three infeed types—modified flank, radial and incremental—and their programming requirements:

For high-speed tapping, YG-1’s Synchro Tap is designed to be extremely free cutting. “The Synchro Tap has very little contact with the workpiece and therefore can run at a much higher spindle speed. The tool has features and geometry to create free cutting. In tapping, your infeed or feed rate is fixed and is based on the pitch or lead of the tap. Your only option for productivity gains is to make the spindle go faster,” Ford explained. “Synchro Taps are designed to be run in a synchronous tapping cycle and held rigidly or, better yet, with a synchronous holder. That allows users to achieve two to three times greater spindle speeds than conventional taps.”

Sandvik Coromant’s wide assortment of threading grades and geometries covers the majority of materials and applications. Burton described the types of threading inserts and their geometries: “There are three different types of threading inserts: full profile for high productivity; V-profile 60° and 55° for most commonly used applications; and multi-point inserts for highly productive, economic threading in mass production.” Sandvik Coromant offers inserts in three geometries: all-purpose for use in a wide range of materials; F-sharp geometry for gummy or sticky materials; and C-chip breaking geometry for low carbon, alloy and some stainless materials.

Technological advances and market forces have resulted in new developments in both indexable and solid carbide thread tooling, according to Jeff Dei, president of Carmex Precision Tools LLC, Richfield, Wis. “Nanotechnology coatings provide more accurate threads and longer tool life. Also, the advent of complex dies has led to the development of newer shapes, providing better cutting geometries,” he said.

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

“In conventional thread production, machining is carried out in two steps: step 1 is pre-drilling and step 2 is machining the threads using either taps, cold-forming taps or thread milling cutters,” said Mark Hatch, product director, adding that the required tool change results in longer machining times.

In deep hole drilling, ramping immediately up to full speeds and feeds can create safety concerns and risk compromising the work. As such, many of Allied’s standard recommendations for general-purpose T-A insert drills can be summed up in one phrase: Approach the pilot hole with caution. For more specifics, see the images in the picture gallery above.

“Taptor features a unique drill section with a few threading teeth that are arranged axially at a small distance from the drill tip to produce threads in blind and through-holes, eliminating one entire machining process—the pre-drilling cycle,” Hatch said. “The core hole and thread are produced simultaneously in one operation by the Taptor tool, which was developed by Emuge-Franken. The process (Audi has applied a patent for it) is basically divided into two steps. In the first step, the movement of the tool corresponds to synchronous tapping. The drill feed per revolution therefore matches the thread pitch. In the second step, the tool cuts free at the drilling depth. And the thread teeth create a circumferential undercut. Then the Taptor is retracted through the generated thread.”

However, the need for careful setup is no excuse to spend inordinate amounts of time identifying and correcting for runout with every tool or insert change. More specifically, there is no room in a modern production environment for climbing into workzones to mount indicators, nor for holding pieces of paper in place for tool touch-offs. Chances are, assembling tools offline with a presetter will save significant amounts of time in any deep-hole drilling operation.

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

In addition to ground inserts and pressed or molded inserts, Iscar offers a combination insert: the B-style insert is especially effective on aerospace materials. The B-style insert is a ground insert with a pressed chip former on the top of the insert which provides a sharp edge for shearing high temperature or gummy materials.

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

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

Carmex has developed a wide selection of material-specific tooling in indexable and solid-carbide versions. “Applications involving hard-to-machine materials and high-temperature alloys have been largely responsible for the development of material-specific tooling,” said Dei. “Thanks to the development of new materials and nanotechnology, we are now able to match the correct coating or coatings to the substrate that will deliver the best results for the specific application. The Slim MT line, for example, which was designed for machining long threads from small to large diameters, utilizes a carbide/coating combination that provides both extended tool life and improved productivity in difficult materials.”

One example is pecking. Periodically reversing the tool’s feed during the cut should not be required to ensure chips evacuate from the hole. “When you see pecking these days, it’s usually someone misapplying a tool or using the wrong tool entirely,” Mr. DeLuca says.

Threading problems may not be talked about much, but they exist. “It’s interesting that when talking to operators, programmers and engineers, if you ask them where they have trouble, almost nobody says threading,” said Luke Pollock, product manager, Walter USA LLC, Waukesha, Wis. “But everyone has had trouble with birdnesting or other chip issues when tapping. We normally try to push end users into thread forming or thread milling if possible. Taps have a very specific design depending on the materials or application, so that creates an issue of possibly making the tool selection very difficult.”

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.

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.

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

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

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?

The most recent addition to Allied Machine’s thread milling products is the solid-carbide AccuThread T3, designed for machining hardened or difficult-to-machine materials, such as stainless steel, tool steel and high-temperature alloys.

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.

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.

Iscar, which offers full lines of both thread milling and thread turning products, has introduced new insert products for thread turning that feature multi-cornered design. “Inserts have five or 10 corners versus two or three corners for standard lay-down threading,” said Hudgins. “The Pentacut format, for example, has five corners and the DecaIQ insert doubles up for 10 corners. DecaIQ threading is more for UN threads, standard threads up to 32 pitch down to 16. The Penta 27 is a wider insert that can create a wide thread geometry such as Acme, stub Acme or a lot of premium coupling threads for oil and gas.”

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

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.

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

The premium AccuThread T3 solid-carbide thread mill is optimized for difficult-to-machine materials. “Since its introduction, AccuThread T3 has been a great success, so we are expanding the line with larger thread sizes up to 1"-8 UN and 24-3 ISO,” said Ripple. “The AccuThread T3 features AM210 multilayer PVD coating and includes left-hand cutting, allowing the tool to climb mill while it moves from top to bottom, creating a right-handed thread. Three cutting teeth cut minimal threads all at once and reduce side deflection as well as cut a precise thread form deeper into materials harder than 55 HRC, even reaching materials and customers with 60 HRC materials.”

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

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

Answer these 10 questions and you will be much closer to threading success the first time around, according to YG-1’s Mark Ford:

Each thread produced corresponds to the specifications of DIN ISO 965 (Metric ISO thread). An undercut is created at the bottom of the thread, the length of which corresponds to the lead-in chamfer of a conventional threading tool. The screw can be screwed into this undercut. The Taptor process can be used on any machine that supports synchronous tapping and has a spindle with torque support and a tool magazine that can accommodate the Speedsynchro Taptor holder.

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

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

In helical indexable tooling. Carmex’s vertical thread milling tools are available in both single- and multi-flute configurations. The multi-flute inserts are available with four to eight cutting edges and can be used both for internal and external threads. The helical shape delivers smooth cutting with low cutting forces, according to the company.

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

A cautious approach, modern thinking, offline presetting and attention to coolant and chips unlock the potential of the latest replaceable-tip drills for deep CNC hole-making applications.

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.

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

For thread turning, Iscar USA, Arlington, Texas, has introduced two new carbide grades, IC 806 and IC 1007, which are well-suited for aerospace materials. IC 806 has had great success in turning and became a good choice for threading, and IC 1007—a hard substrate with TiAIN PVD coating—was similarly effective for threading hard and aerospace material, according to Randy Hudgins, national product manager for turning and threading.

To take the mystery out of selecting the correct tap for an application, Ford developed a training program he calls the 10 Questions to Success (see sidebar). “Answer these 10 questions and you are going to be much closer to success the first time around,” he said. “Shops often don’t know if they have the right tool because it’s such a nuanced little tool. Unlike a drill or an end mill, you can’t adjust your chip load or programming,” he said. “With a tap, you have to design that into the tool to overcome the inability to make adjustments on the fly. When running a tap, the control is such that it will only allow running at a certain percentage of the spindle speed. It’s the one tool where you drive to the bottom of the hole, stop and reverse back out. Every other round tool moves in a forward action.”

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

YG-1’s carbide taps are designed for cast materials, aluminum, and cast iron. They can achieve surface footage upward of 200 sfm, compared with conventional tap’s 150 sfm. “Carbide will absorb an enormous amount of heat and has outstanding wear characteristics, but it tends to be brittle,” said Ford. “Carbide taps require a little different mindset in handling and are well suited to high-volume applications like transfer lines for auto parts.”

According to Burton, GC1125 is the first choice grade for ISO P, M, K, and N materials in CoroThread 266. “This PVD-coated grade combines the superior wear resistance of a coated grade with the edge sharpness and toughness of an uncoated grade. Optimized for steel threading and for medium to high speeds. Benefits and features include high wear resistance and the possibility for fewer passes.”

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.

Other problems can be easier to overlook. “One of the most underestimated inputs in any machining process, even beyond drilling, is the coolant,” Mr. DeLuca says. Given the significant impact of coolant on how chips form, adjusting coolant concentration and flow can also help address problems with discolored “birds’ nests.”

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

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

In many cases, comparing the market share of carbide vs. indexable tooling is really a matter of “apples and oranges,” according to Dei. “For instance, carbide is a must for small-diameter internal applications, including many uses in Swiss-style machining,” he said. “The necessity of clamping and the advantages of multiple cutting edges limits indexable tooling to larger applications.”

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.

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

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

It might be difficult to come up with definitive answers for all of the questions surrounding threading, but the effort to learn about advances in technology is well worth the effort when the results are measured. What are the best roles for solid carbide and indexable threading tools? What are the best solutions for difficult-to-machine materials? New coatings? Geometries? Leading suppliers have loaded their portfolios with the advanced tools to do the job. Here are a few of those tooling solutions and the rationale behind their development.

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.

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.

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.

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.

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

Used in conjunction with the Emuge Speedsynchro Taptor collet toolholder, which has an integrated transmission gear, a higher cutting speed can be achieved, according to Hatch. For example, when machining a cylinder head side with 26 threads M6 2×D in cast aluminum at 0.47” (12 mm) deep, Emuge-Franken reported a time savings of 41 percent, or two seconds per thread, when using the Taptor tool and the Speedsynchro Taptor collet toolholder combination.

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

Incremental Infeed: Normally used with very large profiles and pitches or long work threading cycles where tool life needs to match the length of the thread. Chip control is difficult. Special programming is required.

Sandvik Coromant, Mebane, N.C., offers a comprehensive approach to internal and external thread turning with products and guidelines to optimize performance by material application and industry. The most important threading application considerations are chip control, insert wear, quality of thread and tool life, according to Kevin Burton, product specialist-turning team lead and Scott Lewis, industry specialist-aerospace. Threading performance depends on selecting the right insert type, geometry, infeed and programming for thread forms as diverse as general purpose and general use motion, aerospace, pipe thread and highly specialized proprietary threads for oil and gas industry applications, he said.

Gühring has launched a new range of milling cutters especially for mould

You Might Also Be Interested In