United Grinding has signed an agreement to acquire the GF Machining Solutions division of Georg Fischer AG, aiming to establish a global presence in ultra-precision machining.

Moving from an aging set of five-axis mills to more advanced machines enabled Hendrick Motorsports to dramatically improve its engine production.

Grant funding for workforce training or the purchase of new equipment is an undervalued but complex resource for machine shops. We enlisted an expert to help navigate the process.

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Custom workholding enabled Resolve Surgical Technologies to place all sizes of one trauma part onto a single machine — and cut days from the setup times.

How did the two cutting strategies compare? Kyocera ran a series of cutting tests in 4140 steel, 28-32 HRC, on a Haas VF3-YT vertical machining center with a 50-taper, 30 HP spindle. Here are the results:

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.

High-efficiency milling has gotten a lot of attention in recent years as a way to substantially increase metal removal rates with solid carbide end mills on almost any kind of milling machine. With small stepovers, but faster feed rates and deeper depths of cut, this “constant chip load” cutting strategy can dramatically increase roughing efficiency compared to conventional machining.

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.

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

High feedmilling calculator

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.

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.

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.

Because the cutting force is reduced, you can mill with a much larger depth of cut with a solid end mill, plus get better utilization of the full side of the tool. Bottom line, this method can increase metal removal rates by 50% or more compared to conventional roughing, yet still deliver better tool life. What’s great about this process is that it works on virtually any machining center.

ModuleWorks and Toolpath announce a technology partnership that intends to utilize intelligent cloud-based manufacturing solutions for machining estimation and CAM automation.

Custom workholding enabled Resolve Surgical Technologies to place all sizes of one trauma part onto a single machine — and cut days from the setup times.

The tool crib is the backbone of any machine shop — without the right tools, nothing moves forward. While most ERP systems overlook the tool crib, ProShop integrates it seamlessly with CNC programming, job planning, scheduling and more. Join this webinar for an exclusive look at how Roush Yates Manufacturing Solutions leverages ProShop to document tool requirements, sync tool demand from CAM software and efficiently manage the tool crib and work instructions. Discover how ProShop transforms the tooling workflow to maximize efficiency and precision.

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

In this webinar, director of manufacturing Phil Linscheid will discuss how Hamilton Company has transformed its manufacturing operations with real-time production data. Learn how Phil and his team have increased throughput five times since 2017, while simultaneously improving production efficiency. Phil will share his journey over the past few years making strategic decisions to grow the machine shop’s impact as well as how his team uses MachineMetrics to improve production visibility, automate cycle time tracking, increase machine uptime and enable accurate quoting and planning. Agenda: Enabling production visibility in Nevada’s largest machine shop Improving quoting, planning and scheduling with accurate cycle times The importance of integrating shop floor data with operational systems

The reason that high-efficiency milling wasn’t used more in the past was that toolpaths were difficult to program under differing tool engagement situations such as edge cutting vs cornering inside a pocket. However, several CAM systems today dynamically adjust feeds and speeds for any situation to maintain a constant chip load throughout the cut. Multi-flute cutters have also become available—such as the Kyocera 12 mm 9-flute and 6-flute endmills used in these cutting tests—that are more efficient simply by getting more edges into the cut per revolution, and that enhances tool life and surface finish.

Kyocera’s conclusions from these tests are that for lighter axial depths and a larger radial depth of cut, the high feed cutter will have an advantage. For heavy axial and light radial cuts, the solid tools will be a better choice. From a programming standpoint, maximizing the time cutting metal and reducing non-cutting moves will naturally reduce cycle times, further providing cost saving benefits. Past experience has shown that both methods (high efficiency and high feed) are ultimately effective in improving tool life over conventional machining methods.

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

Facing increasing competition from lower-cost imports, Suburban Tool made a move toward large-scale, in-house machining. By identifying a niche in large, precision angle plates and tombstones, the company has strengthened its ability to control quality and protect its reputation.

By equipping MassRobotics with its advanced cobots, ABB aims to facilitate the creation of new and impactful solutions that address real-world challenges across various industries.

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.

Pacon Mfg, Inc. has not rested on its laurels as the 2020 Top Shop Honoree for Shopfloor Practices and Performance. In the years since, it has refined its processes to continue excelling in a volatile market.

Soraluce’s wide range of machine heads and the ability to have multiple heads on a single machine (with automatic changing stations) provides flexibility and reduced setups for large-format machining.

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

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."

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?

Differential gaging measures using two devices, which has advantages over standard, comparative measurements using a single sensing head. These include the ability to measure size without regard to position.

High feed milling with an indexable tool is pretty much the opposite. Here, you are primarily cutting with the end of the tool where the inserts are, and at a shallow depth of cut. The chip thinning principle is applied here too, though now in the axial direction.

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

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.

Cut 4 confirmed that the 1” high feed cutter showed an advantage that wasn’t as large as the metal removal calculation predicted. In this case, the high feed cutter made a lot of non-cutting moves to return to center and also ended up not maximizing the width of cut due to the pocket geometry. In contrast, the high efficiency toolpath allowed the solid carbide tool to stay in the cut a higher percentage of the time and allowed it to close the time gap.

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

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

At Mill 19, the site of the Advanced Robotics for Manufacturing Institute and Carnegie Mellon University’s Manufacturing Futures Institute, robotics data provides the foundation for AI and digital twins.

Kennametal can recommend a drill size that will leave an appropriate amount of material for the reamer to efficiently size the finished hole.

Cut 3 ended up being a much closer race than the metal removal rate calculation predicted. The 12-mm solid tool’s calculated metal removal rate of 2.41 cubic inches per minute was 42% better than the ½ inch indexable cutter’s 1.70 in3, but the cycle time ended up being only 3% shorter. Again, we can attribute this to the high feed tool staying in the cut longer. The high-efficiency tool taking a trochoidal tool path is constantly moving in and out of the cut and results in the cycle time being longer than predicted by the metal removal rate.

Pacon Mfg, Inc. has not rested on its laurels as the 2020 Top Shop Honoree for Shopfloor Practices and Performance. In the years since, it has refined its processes to continue excelling in a volatile market.

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.

This presentation focuses on the vital role that linear and angular encoders play in ensuring precision in machine tools. Attendees will learn about the common challenges compromising accuracy, such as thermal expansion, mechanical misalignments and vibration. Whether you're an OEM, integrator, or machine operator, this webinar will offer valuable insights into optimizing CNC performance. Agenda: Challenges to CNC machine accuracy Understanding encoder technology How encoders address accuracy challenges

Rob Guiao, Chris Hall and Bassanio Peters will demonstrate relatable situations to equip you with data to improve predictability, future-proof operations and maximize ROI. Agenda:  Explore the importance of data in decision-making, especially for facility upgrades or new projects Learn how comprehensive solutions for manufacturing and construction projects can improve predictability and ROI See real demonstrations of machine integrations, facility layouts and automations to ensure proper throughput and integration

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.

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

ModuleWorks and Toolpath announce a technology partnership that intends to utilize intelligent cloud-based manufacturing solutions for machining estimation and CAM automation.

High FeedEnd Mill

Facing increasing competition from lower-cost imports, Suburban Tool made a move toward large-scale, in-house machining. By identifying a niche in large, precision angle plates and tombstones, the company has strengthened its ability to control quality and protect its reputation.

Even before inspection, Datanomix and Caron Engineering’s TMAC AI can extrapolate part quality from cut information. This information also helps shops push their tool life to its limits.

Coordinate systems tell a CNC machine where to position the cutting tool during the program’s execution for any purpose that requires the cutting tool to move.

Coordinate systems tell a CNC machine where to position the cutting tool during the program’s execution for any purpose that requires the cutting tool to move.

At Carnegie Mellon University’s Manufacturing Futures Institute, researchers use a robotic test bed where AMRs deliver Lego bricks to robot arms for assembly to study AI, multirobot collaboration, assembly, safety and more.

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

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.

Kennametal high-feed mill

No matter what your workholding application, automation always makes sense. Kurt Workholding helps you pick the right tool for the automation job — whether it be a single-vise setup or multiple vises holding large work pieces. This webinar will cover automation solutions using pneumatic, hydraulic and electronic actuation. Agenda:  Most common types of vise automation solutions How to pick the right type of automation for an application Key differences between custom workholding and off-the-shelf automation solutions

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

Take a look inside James Engineering, a high-end CNC Deburring OEM that became a job shop when they decided to produce their own parts in-house.

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.

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."

OnLogic is partnering with AI development and implementation specialists to help companies use AI-powered solutions, aiming to drive real business value.

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.

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.

Cut 2 resulted in the high feed cutter having a shorter cycle time while the metal removal rate showed that the solid tool should have been faster. You can see in the video that the high feed cutter is both climb and conventional milling, so it stays in the cut a higher percentage of the time. Since the solid endmill is only allowed to climb mill, there is a lot of time wasted feeding back around to the start of the cut. However, in both Cut 1 and 2, the solid cutter does provide a significantly better surface finish.

The combination of new cutting tool designs and CAM technology are enabling remarkably higher metal removal rates and longer tool life. Here are two cutting strategies you need to understand to get more production out of your machining centers.

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

The goal of National Composites Week is to celebrate and bring attention to the myriad ways that composite materials and composites manufacturing contributes to the products and structures that shape the American manufacturing landscape today. Learn how you can participate in this year's National Composites Week on NationalCompositesWeek.com.

Sandvik high-feed mill

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.

The first shouldering cut shown in the video below is pretty straightforward. With a 1-inch, 5-insert indexable cutter compared to a 12-mm, 9-flute solid carbide endmill, their respective metal removal rates indicate that the solid tool should take roughly 2.3 times as long to machine the form as the high feed cutter, and the actual time reflected this. Note that the high-efficiency process typically only uses climb milling, which is why you see the tool constantly feeding in one direction.

The MFG Meeting brings together manufacturing technology industry leaders to address key business challenges and provide actionable solutions. Sessions cover a wide range of topics, including workforce, economics, supply chain, leadership, politics, and more. This unique meeting experience provides unparalleled opportunities to network with executives from companies that make, sell, service, and support MT. These peers and competitors will learn from each other, build long-lasting connections, and share insights that will benefit their business.

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

High feedinserts

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.

However, extremely high efficiencies can also be achieved with new indexable cutters at shallow depths of cut, but substantially higher feed rates.

Determining the shape of a workpiece is required in many manufacturing processes. Keep in mind these important points to ensure that you master the process.

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.

Which is best? To help answer that question, well-known cutting tool manufacturer Kyocera Precision Tools—which makes both types of tools—ran a series of cutting tests to see how each would perform in side-by-side comparisons. Here’s what they found out.

WIDIA high-feed Milling cutters

A common misconception is to leave too little material for the reamer to remove. The reamer needs enough material to make its cut. Too little material will cause the reamer to rub or burnish and results in accelerated wear and poor surface finish.

Moving from an aging set of five-axis mills to more advanced machines enabled Hendrick Motorsports to dramatically improve its engine production.

The high feed cutting strategy can also be applied on almost any machining center, but because of that, feed rates are much higher, and with a higher chip load per tooth, this process will benefit from a more powerful machine.

Besthigh feedmilling cutter

PTXPO 2025 is a comprehensive showcase of cutting-edge technologies and innovations within the plastics molding industry. Join fellow molders, moldmakers, brand owners, OEMs and their full suite of suppliers in Rosemont, IL for three days of non-stop networking, education and business development opportunities.

SmartBox 2.0 integrates advanced communication protocols and edge computing for enhanced productivity and security, ensuring safe data export from machines to factory networks.

The sheering action of the endmills used in the test cuts is further enhanced by Kyocera’s MFH-Mini cutter design using convex helical inserts that reduce the impact as the edge enters the material, reducing cutting force and vibration. The tool is extremely versatile with the ability to slot, ramp, pocket, face mill and contour. Another benefit is that replacing inserts is less costly compared to solid carbide tools.

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.

High feedmill for aluminum

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.

AI technology isn’t just a concept for the future—it’s here now, ready to transform your estimating process with the new AI BOM builder in JobBOSS². In this first-launch webinar, discover how AI can revolutionize bill of materials (BOM) entry in your shop, saving time, reducing errors and boosting efficiency. In this session, ECI will review how to use AI to build BOMs through a powerful feature that automates the extraction and input of BOM data from PDFs, Excel spreadsheets and images, all within JobBOSS². You'll have the opportunity to watch a live demonstration of the AI BOM builder in action — showcasing its ability to reduce BOM entry time from hours to mere minutes — thereby allowing you to focus on more strategic tasks. Additionally, you will learn about the real-world benefits of AI-driven BOM entry, including the minimization of manual errors, enhanced accuracy, and streamlined estimating processes — all of which can provide your shop with an immediate competitive edge. Finally, there will be a Q&A session with experts, giving you the chance to ask questions and find out how to integrate AI effectively. Agenda:  Experience AI in action in a real-world manufacturing setting Discover how the AI BOM builder can immediately impact your shop’s efficiency and productivity Get hands-on insights on implementing AI to streamline your operations

Motul announces it has acquired Chem Arrow Corp., aiming to expand the global presence and growth in lubricants for metal parts manufacturing.

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.

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

Determining the shape of a workpiece is required in many manufacturing processes. Keep in mind these important points to ensure that you master the 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.

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.

Pacon Mfg, Inc. has not rested on its laurels as the 2020 Top Shop Honoree for Shopfloor Practices and Performance. In the years since, it has refined its processes to continue excelling in a volatile market.

OnLogic is partnering with AI development and implementation specialists to help companies use AI-powered solutions, aiming to drive real business value.

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

CloudNC introduces the resource-efficient Cycle Time Estimator function for its AI-powered CAM Assist solution, available for Mastercam, Autodesk Fusion and Siemens NX CAM users.

Cutting speeds should be about two-thirds that of drilling SFM for similar material and feeds should be two to three times higher.

Each year Products Finishing partners with thousands of finishing operations in the U.S. to celebrate National Surface Finishing Day (NSFD) on the first Wednesday in March. NSFD is designed to celebrate and showcase the industry to trade schools, businesses, officials and media, as well as to celebrate employees and staff. The overarching goal of NSFD is to bring further awareness to the important roles plating and coating facilities play in their communities. Facilities are encouraged to host events and work with local media to build awareness about the contributions made by the surface finishing industry. For a helpful guide to reaching out to media outlets, download the NSFD toolkit here. How can you celebrate? Share your company’s story Hold an open house where the public can check out your facility –— either in person or virtual Offer student shop tours to local trade schools Invite local elected officials to visit and get to know your staff Celebrate your employees Share news about what you’re doing on social media and use the hashtag #NationalSurfaceFinishingDay or #NSFD

High-efficiency milling is based on the “radial chip thinning” theory that’s been around for a long time. The basic idea is to keep the tool cutting at an ideal chip load. To increase the metal removal rate, the stepover is substantially reduced from the typical 50% of tool diameter, but the feed rate is increased in order to maintain the correct chip thickness.