Horn offers tools capable of turning and drilling - carbide insert turning tools

 2024-06-27 07:00:55

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

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

Sandvik Coromant’s multidirectional platform, CoroTurn Prime, is more than just a tool and insert. CoroTurn Prime comprises specific tooling and software that allow for higher material removal rates, longer tool life, and better machine utilization, according to the company. CoroTurn Prime is a family of multidirectional turning tools that have a combination of small entering angles and over and under coolant capability. Currently, the company offers two types of CoroTurn Prime tools: A-type and B-type inserts. A-type inserts have three corners designed for light roughing, finishing, and profiling. B-type inserts are double-sided negative inserts with four cutting edges (eight total edges) designed for roughing and finishing.

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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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.

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.

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Both inserts create thin, wide chips, which spread the load away from the nose radius. This results in increased tool life or allows for increasing the cutting data.

Each multidirectional tool can perform roughing and finishing. Because there are two separate cutting edges, tool life of the entire tool is high.

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.

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.

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.

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

This leads to both better machine utilization, because fewer tool changes are needed, and faster cycle times. It starts with the tool itself and is aided by advanced programming, unique insert geometry, and machine movement.

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.

Tungaloy has two tools in this space, if you don’t include its multidirectional Y-axis insert. One mimics a traditional CNMG insert, and one mimics a VNMG insert for undercuts and profiles.

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

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

Think of Sandvik Coromant’s multidirectional turning as the complete package; a system developed to consolidate insert inventory, enhance productivity, and improve tool life while using unique software.

This rail design, called Y-PRISM, has a rail on the shim/toolholder and matching slot on the insert for tight interlocking and secure clamping. It helps prevent cutting forces from affecting the tool position in any direction and ensures high stability.

“Because you can use the same insert to rough and finish, you can free up a slot in the turret for another turning tool,” Brake.

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.

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.”

According to Brake, roughing cycle times can be reduced by as much as 30 per cent with proper implementation of the CoroTurn Prime tooling and methodology. This is achieved with the higher productivity that the high feed side is capable of.

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“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.”

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

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.

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

Another option is the 3C-TCMT, a single-sided, three-corner insert. It also enables higher feeds during pull turning when compared to ISO tools and also performs push turning.

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“We do understand that most people have already made an investment in a large CAM package, and that’s why Sandvik Coromant has partnered with CAM providers to program CoroTurn Prime inside of their systems,” said Brake.

“The other major difference is that this insert is held differently,” said Gill. “This insert is held by a top clamp, but it also includes a rail design. When you are cutting at a higher feed rate, you now have much more effective clamping.”

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

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.

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“Multidirectional tools can be implemented easily,” said Hartej Gill, product manager for Tungaloy Canada. “We give manufacturers a piece of code with the special program required.”

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.

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

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.

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.

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

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

Multidirectional turning tools (a.k.a. all-directional tools) have been around for a few years now. As more tooling suppliers enter the space, it’s important to get an understanding of how these tools can help you turn parts better. And it all starts where the carbide meets the metal.

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CoroPlus Tool Path is a cloud-based software that can be purchased by annual subscription. This software allows feature-based programming of CoroTurn Prime tooling. Other systems capable of creating similar code for CoroTurn Prime tools include Gibbscam, Mastercam, Siemens NX, CamWorks, and TopSolid.

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.

Multidirectional turning tools can work in both directions (away from and toward the chuck) and perform roughing and finishing (with the top and bottom of the insert) with a single tool. They also perform multiple turning operations like profiling and facing.

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

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

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Another option for multidirectional tooling is purchasing the tool and augmenting your G-code program.

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.

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.

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

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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.

Increasing your material removal rate. Reducing the number of tool changes. Lowering cycle times. Creating a 90-degree shoulder. Profiling and facing with one tool. Roughing and finishing with one tool. Does any of this sound good to you?

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.

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.

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

The system can perform traditional facing and turning paths, like a CNMG 432 insert (end forward and side forward turning). Additionally, it can also perform side backward or face backward turning when engaged on the high productivity or chip thinning side.

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

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.

Joe Thompson has been covering the Canadian manufacturing sector for more than two decades. He is responsible for the day-to-day editorial direction of the magazine, providing a uniquely Canadian look at the world of metal manufacturing.

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

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.

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

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

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

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.

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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.

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

“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.”

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

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

“This insert, although it's a triangular-shape insert, has 12 cutting edges instead of six that you would expect from a TNMG-style insert because you can cut from each side of each cutting edge,” said Gill. “When you are push turning and pull turning, you're using different sides of the insert, effectively increasing tool life.”

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

“All-directional turning is not necessarily new, but the tools that we would customarily use for all-directional turning were round inserts or neutral-handed inserts, and you can’t create square corners with those shapes. The newer inserts may look similar to ISO inserts in some regard, but geometries and technologies are put in place for chip breaking,” explained Keith Brake, regional product manager, turning - Americas for Sandvik Coromant. “For the multidirectional process to work, with chip control in mind, they are now their own specific shape, at least for Sandvik Coromant.”

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

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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.

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.

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 advice from Gill is to roll-in to the workpiece when entering the cut and feed the tool at 0.008 in. per revolution (IPR). When turning away from the main chuck, the cutting edge’s contact with the workpiece becomes larger, generating a pull greater cutting force, as compared to a push force when turning towards the chuck. He also advises that tailstock support should be used.

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.

The tool families of 6C-TOMG and 6V-TOMG are double-sided, six-corner inserts with 80-degree or 35-degree corner angles. For pull turning, they can be used at high feeds to improve productivity by roughly 200 per cent when compared to traditional turning ISO tools. The same tool also performs push turning using the same cutting edge angle as standard ISO tools.

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

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This leads to fewer tools needed in the turret but also fewer tools needed in your tool crib. The multifunctional nature of these tools also eliminates tool changes, so cycle time is affected as well.

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.”

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“It should maybe be thought about as two different tools, one to rough and one to finish,” said Gill. “In this case, you're using this backside as a roughing edge and the frontside as a finishing edge. This reduces the number of tools you need.”

“The front of the insert is like a regular CNMG insert with 80-degree angle and five degrees of clearance. It behaves like a regular CNMG insert because it has the same shape as that type of insert,” said Gill.

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

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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.

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

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 example, a CNMG 120408 may commonly run a 3 mm depth of cut in the range of 0.4 mm per revolution (MPR) feed rate whereas the Prime B insert has the capability of reaching 0.75 to 0.95 MPR feed rate at that same depth of cut. Of course, horsepower and quality of setup play a very large role in the overall success of the application,” said Brake. “It’s a combination of the way the program is created to properly enter the workpiece, and the way the inserts are designed. It’s just physics. We are leveraging physics to thin the chip with a shallow entering angle.”

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

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

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.

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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.

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!

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.

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

Multidirectional tools are an obvious fit for complex turning applications that require multiple kinds of turning operations to be performed. However, that’s not all they are good for.

Sandvik Coromant’s B-type inserts are double-sided negative inserts with four cutting edges (eight total edges) designed for roughing and finishing. Sandvik Coromant

Multidirectional tool can perform roughing and finishing. Because there are two separate cutting edges, tool life of the entire tool is high. Tungaloy Canada

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Multidirectional tooling improves machine utilization, because fewer tool changes are needed, and enables faster cycle times. Tungaloy Canada

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

“Our second generation of CoroTurn Prime is a true eight-edged system. So, if it's properly programmed and properly implemented, you can use the chip thinning side or the high-efficiency side for your roughing application, and then you can turn right around with the same tool and you can use the other side for finishing operations without ever making a tool change,” said Brake.

It’s easy to wrap your head around the fact that cubic inches of material removed per hour is the gold standard of metrics. However, many other factors play a role in the success of a machine operation. Some of them will contribute more than others, but they all help. These tools can stack benefits.

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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.

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.

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

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

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.”

“With multidirectional tools, the common function is to perform both back turning (roughing) and front turning (finishing),” said Gill.

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.

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.

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.

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.

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.

When used properly, it can perform both roughing and finishing applications without changing the tool. This feature helps to reduce carbide usage and conserves turret real estate.

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.

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.

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 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.

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.

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.

“If you’re currently running a CNMG insert with 3-mm depth of cut or less, you can use this system in an existing program. Nothing has to change, and you can get the benefit of chip control that these insert geometries offer,” said Brake. “This can be very important for customers who are running P1 or long-chipping steel. It’s a really simple way to gain chip control if properly applied.”

So that is one difference from a regular insert. The other difference is the ability of these tools to perform high-feed pull turning. The insert is inclined, and, at the same DOC, the chip is wider and thinner, which allows for a faster feed to be used.

Horn offers tools capable of turning and drilling - carbide insert turning tools

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