How To Identify Indexable Inserts - iso carbide insert designations

 2024-07-07 06:32:28

Thick-film CVD diamond can be grown to a thickness equal to that of PCD, up to 1mm. PCD is often bought by the tool manufacturer as a blank with a tungsten-carbide backing. It is then cut by EDM into triangular tips (2mm to 5mm thick). Each tip is open-air brazed onto a tool corner. CVD thick-film diamond is also bought as a blank and is laser cut. (Without the cobalt backing or filler, the diamond is strictly an electric insulator, and hence it cannot be EDMed.) CVD diamond can be brazed readily in large quantities using a vacuum furnace.

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

Under CVD diamond growth conditions, the cobalt in tungsten carbide tools acts as a catalyst for the formation of weakly bonded carbon. This graphitic layer essentially prevents the adhesion of the diamond to the substrate. One solution to this problem is to diamond coat binderless tungsten-carbide tools. Diamond adhesion to cobalt-free carbide is reliable, leading to excellent cutting performance by the tool. However, the cobalt binder used in a tungsten- carbide tool gives the tool its high fracture strength. Without the cobalt binder, diamond-coated carbide tools aren’t as useful.

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.

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

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

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

Seco’s X-tra Long Solid Carbide Drills are designed to achieve fast, reliable performance in steel, stainless steel and cast iron, as well as Inconel, titanium and hardened steel. A specialized tool geometry and coating eliminate chipping and sudden breakage while minimizing flank and center wear, while ground-edge prep produces smoother cutting edges, greater evenness and closer tolerances than brushing. Seco X-tra Long Solid Carbide Drills maintain specified drilling depth after up to three reconditioning cycles.

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 commercial availability of CVD diamond coatings for carbide tools is great news for end users, offering them a chance to cut challenging materials more economically than ever before. Even better news may be the development of inexpensive turnkey diamond-deposition reactors that may permit users to coat their own tools.

Substance used for grinding, honing, lapping, superfinishing and polishing. Examples include garnet, emery, corundum, silicon carbide, cubic boron nitride and diamond in various grit sizes.

Intermetallic compound consisting of equal parts, by atomic weight, of tungsten and carbon. Sometimes tungsten carbide is used in reference to the cemented tungsten carbide material with cobalt added and/or with titanium carbide or tantalum carbide added. Thus, the tungsten carbide may be used to refer to pure tungsten carbide as well as co-bonded tungsten carbide, which may or may not contain added titanium carbide and/or tantalum carbide.

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.

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

One advantage CVD thick-film diamond has over PCD is the fact that thick-film is pure, compared to PCD’s diamond/cobalt composition. The resulting performance improvements are listed in Table 2. Over the past two years, researchers have conducted extensive testing of CVD diamond thick-film vs. PCD. Both products have specific advantages, but thick-film is more abrasion-resistant, and more thermally conductive. Also, thick-film has a lower coefficient of friction and better chemical and thermal stability than PCD. PCD is superior in terms of fracture strength.

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.

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.

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

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

Substances having metallic properties and being composed of two or more chemical elements of which at least one is a metal.

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

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.

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

Seco-Capto MTM JETI Toolholders enable the use of shorter tooling with greater reach, less overhang and reduced collision risk. The decrease in vibration and chatter improve machining results, even with materials that require high-pressure cutting fluid. The toolholder design also enables shops to optimize production and use the same machining tools on more than one spindle.

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.

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

The world market for CVD diamond-coated inserts, based on estimates from large tool manufacturers, is $5 million per year. The current PCD world market is $250 million per year. Perhaps the fastest growing demand for diamond tools comes from the automotive sector, which needs the technology for machining hypereutectic aluminum and new brake-pad composites. The projected growth of the aluminum content in U.S. automobiles, shown in Figure 3, is due in part to impending U.S. government regulations concerning fuel efficiency. (More aluminum means lighter cars, which translates into higher fuel efficiency.) Many of the aluminum alloys to be used contain a high percentage of silicon particulates. As shown in Table 1, these particulates may be harder than tungsten carbide and may severely limit carbide tool life. But diamond tools can handle them with comparative ease.

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 impact of the availability of CVD diamond reactors on the PCD market is large. Toll houses can now replace PCD with their own in-house manufactured thick-film CVD puck. The added control over a critical supply is a welcome change. CVD is much cheaper to make and cuts more parts in many applications. For example, the cost of manufacturing a 2" by 0.5mm CVD puck can be $300, depending upon sales volume. This represents a significant savings over PCD, which costs about $900 for an identical piece.

Currently, most of the major carbide-tool manufacturers possess access to good adhesion technology for CVD diamond on tungsten carbide with cobalt. Tool life in turning applications is now limited by diamond wear—not by brittle substrates, delamination, or spalling. Note, however, that interrupted cutting is still a challenge and work is still being done to improve coating performance in interrupted applications.

Aluminum containing specified quantities of alloying elements added to obtain the necessary mechanical and physical properties. Aluminum alloys are divided into two categories: wrought compositions and casting compositions. Some compositions may contain up to 10 alloying elements, but only one or two are the main alloying elements, such as copper, manganese, silicon, magnesium, zinc or tin.

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

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!

Materials composed of different elements, with one element normally embedded in another, held together by a compatible binder.

Cutting tool material consisting of natural or synthetic diamond crystals bonded together under high pressure at elevated temperatures. PCD is available as a tip brazed to a carbide insert carrier. Used for machining nonferrous alloys and nonmetallic materials at high cutting speeds.

Attend TASC, The Automated Shop Conference, in Novi, Mich on Oct. 11, 2023 for a comprehensive look into how to use automation to transform your machine shop.

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

Abrasive process that improves surface finish and blends contours. Abrasive particles attached to a flexible backing abrade the workpiece.

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

Groove or other tool geometry that breaks chips into small fragments as they come off the workpiece. Designed to prevent chips from becoming so long that they are difficult to control, catch in turning parts and cause safety problems.

Diamond tools have long filled an industry need for machining nonferrous abrasive materials such as high-silicon aluminum. Such materials cannot be machined economically using carbide tools. For many years, tool manufacturers have produced diamond tools consisting of artificial diamond grit manufactured at high pressure and temperature and then compacted, with cobalt as a binder, to produce a solid known as PCD. The PCD is then cut and brazed onto a corner of a cutting tool.

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."

High-temperature (1,000° C or higher), atmosphere-controlled process in which a chemical reaction is induced for the purpose of depositing a coating 2µm to 12µm thick on a tool’s surface. See coated tools; PVD, physical vapor deposition.

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.

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

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

Applied Science and Technology Inc. (ASTeX), Woburn, MA, has developed several commercially available turnkey microwave reactors capable of fully automated diamond deposition over areas up to 12" in diameter (Figure 2). The throughput of the largest ASTeX reactor is 300 SPG-422-style tools coated with 20µm-thick CVD diamond per day. A smaller version capable of coating 50 tools per day also is available.

CVD thick-film diamond also has some distinct manufacturing advantages over PCD. The CVD diamond can be grown on a mirror-smooth surface, typically a silicon wafer or a molybdenum puck. After deposition the diamond can be released from the substrate to yield a mirror-finish top surface for the tool tip. This obviates the top polishing required by PCD. CVD thick-film can be deposited over areas up to 12" in diameter. The versatility and affordability of laser cutting enables custom manufacturing of diamond cutting edges of practically any shape.

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

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

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

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

The company’s expanded tooling lineup is aimed at applications ranging from general ISO turning to high-volume hard turning and deep-hole drilling.

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

3) Purchase a diamond-coating reactor for in-house coating (ASTeX, Woburn, MA). In terms of profit margin, this option is the most attractive, but it requires access to adhesion technology. Table 3 breaks out the costs for in-house production using a single reactor.

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

Diagnosing when a tool is failing is important because it sets an expectation and a benchmark for improvements. Finding out why gives us a clue for how to fix it.

Hardness is a measure of the resistance of a material to surface indentation or abrasion. There is no absolute scale for hardness. In order to express hardness quantitatively, each type of test has its own scale, which defines hardness. Indentation hardness obtained through static methods is measured by Brinell, Rockwell, Vickers and Knoop tests. Hardness without indentation is measured by a dynamic method, known as the Scleroscope test.

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

The company also has two new grades of PCBN inserts for high-volume production of automotive and other industry components: the CH1050 grade for finishing and the CH2581 for semi-interrupted cuts. CH1050 offers high-accuracy edge prep and is designed for extended tool life and lower cost per part. CH2581 features a high-accuracy edge prep and physical vapor deposition (PVD) coating to enable faster speeds and higher throughput for reduced part costs.

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.

Seco’s MF2 chipbreaker on RCMT/RCGT round, positive-style ISO-turning carbide inserts maintains favorable chip control at higher speeds and feeds, especially with dynamic turning. One series of stable, durable, carbide round insert grades handles a wide range of turning operations, from roughing to finish turning.

Cutting tool materials based on aluminum oxide and silicon nitride. Ceramic tools can withstand higher cutting speeds than cemented carbide tools when machining hardened steels, cast irons and high-temperature alloys.

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.

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

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

When cobalt-enriched carbide tools are coated with CVD diamond, the life of these tools is severely limited by delamination and spalling of the coating. In recent years, however, several companies and research institutions attempted to solve the problem of diamond adhesion to standard carbide grades. Several successful adhesion-promoting treatments have been reported. So far, success has been limited to carbides with a maximum of 6% cobalt, which is C-2 carbide, the most widely used carbide grade. The most successful approach has been to etch the cobalt from the surface layer using wet, electrochemical, or plasma etching techniques. It was found that removing the cobalt from the surface region to a depth of 5µm to 10µm does not significantly weaken the substrate but does dramatically increase adhesion of diamond to the surface.

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

At the 1994 International Manufacturing Technology Show in Chicago last September, four tool companies—Crystallume, Menlo Park, CA; Sandvik Coromant Co., Fair Lawn, NJ; Kennametal Inc., Latrobe, PA; and Teledyne Advanced Materials-Cutting Tools, La Vergne, TN—displayed CVD diamond-coated carbide inserts. Statements from other big firms such as Valenite Inc., Madison Heights, MI; Mitsubishi Materials Corp., Garden Grove, CA; and Carboloy Inc., Detroit indicated that they too would soon be offering CVD diamond carbide tools.

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

Roy Gat is a research scientist in the diamond and process products group at ASTeX. He is responsible for tool-coating-process development.

CVD diamond tools have been found to excel in the cutting of green ceramics, graphite- or fiberglass-reinforced composites, brass, bronze, metal-matrix composites (such as A-359 aluminum/SiC and 6061 aluminum/Al2O3), magnesium alloys, plastics, and laminates. Table 1 shows that the hardness of the particulates present in some aluminum alloys is greater than that of tungsten carbide. This leads to rapid tool failure when an uncoated carbide tool is used on these alloys. Diamond, however, because of its extreme hardness, does an excellent job of machining these materials without sacrificing tool life.

Because of recent technological advancements such as the ASTeX reactor, smaller toolmakers can now participate in the CVD diamond market. One form of participation is known as toll coating. Here, a company offers to diamond-coat another manufacturer’s tool. For example, Teledyne’s CVD diamond products are actually coated by a small firm named sp3, Mountain View, CA. Other forms of participation for smaller tool houses include coating custom tools and manufacturing thick-film CVD diamond for PCD replacement. As a result of smaller companies getting involved, users will get to choose their CVD diamond tools from a greater number of tool manufacturers than they might have expected.

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.

The quality of a CVD diamond coating’s adhesion to the underlying tool surface depends on the tool material. The adhesion of a diamond coating to Si3N4 is good. CVD diamond-coated Si3N4 tools outperform PCD tools in many cutting applications, such as the machining of graphites and polymer composites. While diamond coatings improve the performance of a Si3N4 tool, they cannot overcome some of the inherent shortcomings of Si3N4 itself, such as poor fracture strength. That’s why so much effort in recent years has gone into CVD diamond-coating carbide tools.

Angle of inclination between the face of the cutting tool and the workpiece. If the face of the tool lies in a plane through the axis of the workpiece, the tool is said to have a neutral, or zero, rake. If the inclination of the tool face makes the cutting edge more acute than when the rake angle is zero, the rake is positive. If the inclination of the tool face makes the cutting edge less acute or more blunt than when the rake angle is zero, the rake is negative.

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.

Machining operation in which metal or other material is removed by applying power to a rotating cutter. In vertical milling, the cutting tool is mounted vertically on the spindle. In horizontal milling, the cutting tool is mounted horizontally, either directly on the spindle or on an arbor. Horizontal milling is further broken down into conventional milling, where the cutter rotates opposite the direction of feed, or “up” into the workpiece; and climb milling, where the cutter rotates in the direction of feed, or “down” into the workpiece. Milling operations include plane or surface milling, endmilling, facemilling, angle milling, form milling and profiling.

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.

2) Utilize a toll coating service offered by a company that has adhesion technology, such as Crystallume or sp3.

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

Seco Tools has introduced new toolholders, PCBN inserts, round carbide inserts and extra-long solid carbide drills aimed at applications ranging from general ISO turning to high-volume hard turning and deep-hole drilling.

CVD diamond-coated carbide tools offer several advantages over uncoated carbide and PCD tools. A diamond-coated carbide tool can typically manufacture more than 10 times as many parts as an uncoated carbide tool can. CVD technology also makes it possible to coat complex tool shapes, such as inserts with chipgroove geometries. Such shapes are not readily available through PCD technology. Also, CVD diamond in its thick-film form is a cheaper, more effective replacement for PCD composite in brazed tools.

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

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.

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.

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.

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.

Process that vaporizes conductive materials by controlled application of pulsed electrical current that flows between a workpiece and electrode (tool) in a dielectric fluid. Permits machining shapes to tight accuracies without the internal stresses conventional machining often generates. Useful in diemaking.

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

So far, Made in the USA has looked into system-wide effects of broken supply chains, automation, skilled workforce issues and our perception of manufacturing jobs — examining each topic through a prism of individual experiences. For this final episode for Season 1, let’s look at one more system-wide question and bring it back to personal perspectives: Is there today a new dawn, a new moment for American manufacturing?

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

Extremely hard material added to tungsten carbide to reduce cratering and built-up edge. Also used as a tool coating. See coated tools.

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.

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

Thin-film diamond coatings for cutting tools are typically 0.001" (25µm) thick. The coatings are kept thin to maintain the cutting-edge sharpness. The rake and flank of the tool are both coated. The diamond coating conforms to all geometries, including chipbreaker designs and custom-tool geometries. While a PCD blank can be brazed onto only one corner of an insert, CVD diamond can coat all corners. This allows diamond-coated tools to outperform PCD tools in some tool-life tests. The promise of CVD coating is a cheap, throwaway tool that provides the performance of PCD, while requiring no resharpening of the diamond and the attendant costs of inventory and tracking.

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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.

The first in-person IMTS in four years left the MMS editorial staff with a lot to digest. Here are a few of our takeaways from the show floor.

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.

Making diamond films at low pressures is a remarkably simple process. CVD diamond is made when a mixture of between 1 and 5 atomic percent methane in hydrogen is chemically excited to produce hydrogen and hydrocarbon radicals. In most commercial systems, excitation is performed using microwave radiation. A diamond film is formed on a surface held to about 900°C in proximity to the excited gas. Typical pressures are subatmospheric (20 to 100 Torr) and deposition rates for tool applications range between 0.1µm/hr. and 10.0µm/hr., depending on the design and power of the reactor.

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.

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.

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

Seco have also used its specialized, 3D-printed coolant clamp to deliver Jetstream Tooling high-pressure cutting fluid directly to the cutting edge. With a range of single-screw coolant clamp options for specific applications and depths of cut, these toolholders provide fast setup and indexing, making chip control less of a challenge on 45-degree B-axis multitasking machines.

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

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

Carbide and high-speed-steel tools coated with thin layers of aluminum oxide, titanium carbide, titanium nitride, hafnium nitride or other compounds. Coating improves a tool’s resistance to wear, allows higher machining speeds and imparts better finishes. See CVD, chemical vapor deposition; PVD, physical vapor deposition.

Ultimately, the acceptance of CVD diamond tool products will depend on their performance and price, especially in comparison to PCD tools. The availability of commercial CVD diamond reactors enables both large and small tool houses to compete favorably on both these points with PCD suppliers. For thin-film diamond, the end user now has three options:

The good news for end users is that they now have the happy problem of deciding when to use PCD tools and when to use CVD diamond-coated carbide tools. Let’s examine how CVD diamond coating works and why it is such an important advancement in coating technology.

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

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.

It was a long time coming, but all those promises about CVD diamond-coated carbide tools are finally being fulfilled. And just about every carbide toolmaker in the United States is after a piece of the action.

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 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.

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.

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

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

Sunnen Products Co. is celebrating its 100th anniversary, highlighting the history of its line of honing and precision solutions.

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.

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

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.

Cutting tool material consisting of polycrystalline cubic boron nitride with a metallic or ceramic binder. PCBN is available either as a tip brazed to a carbide insert carrier or as a solid insert. Primarily used for cutting hardened ferrous alloys.

Tangential velocity on the surface of the tool or workpiece at the cutting interface. The formula for cutting speed (sfm) is tool diameter 5 0.26 5 spindle speed (rpm). The formula for feed per tooth (fpt) is table feed (ipm)/number of flutes/spindle speed (rpm). The formula for spindle speed (rpm) is cutting speed (sfm) 5 3.82/tool diameter. The formula for table feed (ipm) is feed per tooth (ftp) 5 number of tool flutes 5 spindle speed (rpm).

1) Buy from one of several tool firms offering diamond-coated tools. These include Crystallume, Kennametal, Norton (Si3N4 tools only), Sandvik, and Teledyne. Typical price for a diamond-coated carbide tool at the IMTS show was $60.

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

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).

This synthetic diamond for cutting tool applications is an agglomeration of small (typically 1µm- to 10µm-dia.) crystals (Figure 1). Each crystal is virtually identical to natural diamond and high-pressure synthetic diamond, only purer in most cases. Each crystal is bound strongly to its neighbors as evidenced by transgranular fracture surfaces.

Added to titanium-carbide tooling to permit machining of hard metals at high speeds. Also used as a tool coating. See coated tools.

Workpiece is held in a chuck, mounted on a face plate or secured between centers and rotated while a cutting tool, normally a single-point tool, is fed into it along its periphery or across its end or face. Takes the form of straight turning (cutting along the periphery of the workpiece); taper turning (creating a taper); step turning (turning different-size diameters on the same work); chamfering (beveling an edge or shoulder); facing (cutting on an end); turning threads (usually external but can be internal); roughing (high-volume metal removal); and finishing (final light cuts). Performed on lathes, turning centers, chucking machines, automatic screw machines and similar machines.

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.

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About the AuthorRoy Gat is a research scientist in the diamond and process products group at ASTeX. He is responsible for tool-coating-process development. Stacy Swider is lead reliability engineer, and Edward Kelly is marketing manager at ASTeX.

1. Flexible portion of a bandsaw blade. 2. Support material behind the cutting edge of a tool. 3. Base material for coated abrasives.

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

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.

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

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

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

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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.

How To Identify Indexable Inserts - iso carbide insert designations

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