Inspired partnerships for improved production - carbide insert supplier

Too many shops made up their minds about cermet inserts too long ago, says Scott Pettay, a cutting tool application engineer. Cermets today deserve a second look.

A Melin multiflute cutter removes difficult burrs using a CAM-generated toolpath, according to the company.

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

When Puneet and Neelam Neotia moved from India to the United States several years ago, they brought with them a family background in manufacturing and CNC machining. Now the couple is working to get their startup machine shop off the ground, sourcing new customers and getting the word out about their shop in Clarksville, Indiana. The couple — proud to publicize their "Made in the USA" parts — is leveraging family connections and manufacturing capabilities back in India, but not in the way that some people assume.

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

Take the perception that cermets can only handle light cuts. Historically, these inserts have machined at depths not much greater than 0.060 inch, but today, cermet inserts routinely cut steel at depths reaching 0.120 inch. Then there is the perception that cermets are brittle. While cermets of the past were more uniformly vulnerable to impacts and thermal shocks, cermet inserts today are tougher—some of them offering flexural strength equal to that of P15 carbide.

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

Women in Manufacturing is excited to announce that the 2024 SUMMIT will be a hybrid event — both an in-person and virtual experience. Both program offerings will enable you to grow through education and connections that are insightful, meaningful and actionable. Join Women in Manufacturing Oct. 6-9, 2024, in Boston or digitally for an event filled with plant tours at leading manufacturing facilities, professional development sessions, roundtable discussions on important topics, and inspiring keynotes.  All while engaging and interacting with peers through social and networking events! __PRESENT __PRESENT

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.

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.

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.

Like his peers, Alex suggested reducing the feed by at least half when breaking into the cross-hole. “Once you’re in the clear, you can go faster, at least until the far side of the cross-hole. That’s where I recommend really dropping the feed rate, maybe a thou or two per rev, so the drill doesn’t walk. Finally, once the point angle is fully engaged, you should immediately increase the feed rate again so you don’t have chip control issues.”

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

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

• Use high-pressure, high-volume coolant to promote chip evacuation, reduce heat and lubricate the cutting tool.

And there’s no argument on feeds and speeds. “Until you get to the cross-hole, you’re going to run the recommended feeds and speeds,” Brown said. “If it’s a really deep hole, you have to go a bit lighter. As a rule, we tell people to reduce the feed rate when cross-hole drilling. The problem is that you give up good chip formation when you do that, but you help ease the transition into the cross-hole. And once you engage fully on the other side of the hole, you can go back to normal.”

To this list, Mr. Pettay adds a fifth application that may become more prominent over time: dry machining. Cermets’ limited ability to withstand coolant is a disadvantage only where coolant is used. As coolant disposal costs continue to rise, dry machining may represent a growing share of metalworking processes, potentially providing further reason why cermets deserve a second look.

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.

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!

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."

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.

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

Coated cermets are a different matter, however. These tools can actually excel in the machining of stainless steels. For safety, when machining nickel-containing materials, coated cermets are recommended.

Certain materials do present problems, however. The source of these problems often relates to nickel.

Cross-hole drilling is challenging work, but these tips should point you in the right direction. If not, call your cutting tool rep. You’ll be crossing holes in record time. CTE

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 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.

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

About the Author: Kip Hanson is a contributing editor for CTE. Contact him at (520) 548-7328 or khanson@jwr.com.

In the late 1800s, a new technology — Swiss-type machines — emerged to serve Switzerland’s growing watchmaking industry. Today, Swiss-machined parts are ubiquitous, and there’s a good reason for that: No other machining technology can produce tiny, complex components more efficiently or at higher quality.

According to Dan Habben, applications engineer at Sumitomo Electric Carbide Inc., Mt. Prospect, Ill., cross-holes are always a problem child. “Probably the best tip I can give is this: don’t do it!” laughed Habben, who works with automotive suppliers and sees cross-holes in everything from transmission housings to hydraulic valves for diesel engines. “Our customers cut a lot of die-cast aluminum and gray cast iron, and one of the main problems we see, especially with aluminum, is burrs. In hydraulic systems, it’s important to get a clean hole. Any chips or hanging chads left in the workpiece might pass into the hydraulics, damaging a valve or pump.”

Rob Brown, product manager for Allied Machine & Engineering Corp., Dover, Ohio, agreed with most of that advice. “As far as insert drills go, they’re absolutely right. There’s no margin on those tools and only a single effective cutting edge. On spade drills, however, the margin runs the length of the insert itself. Sure, that’s all the support you’re going to get, but it’s still a lot more than you’d get with an insert drill.”

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.

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.

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.

All kidding aside, the product works through a patented mechanism utilizing a flexible shaft together with a polished disk that acts like a cam follower against the hole wall, allowing the Orbitool to cleanly and effectively remove cross-hole burrs.

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

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

“You need some sort of support to keep the drill stable when you break through into the cross-hole,” Zaitoon said. “With an insert drill, there’s no margin behind the cutting edge to stabilize it like there is with other drills.”

That’s music to anyone’s ears. J.W. Done guarantees its product, whether it’s used to replace traditional manual deburring processes or in a CNC machine tool. “People ask us why we don’t have any product returns,” Kapgan said. “I tell them it’s because we don’t give a return address.”

Microprocessor-based controller dedicated to a machine tool that permits the creation or modification of parts. Programmed numerical control activates the machine’s servos and spindle drives and controls the various machining operations. See DNC, direct numerical control; NC, numerical control.

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.

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.

Like his competitors, Brown said edge preparation is key. “We grind a chamfer, what we call an SK2 corner clip, on the outer margin of the drill. This helps stabilize the tool while improving tool life and reducing burr formation. From a cross-hole standpoint, the secret is in the stability of the tool.”

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

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

There are usually better solutions to chatter than just reducing the feed rate. Through vibration analysis, the chatter problem can be solved, enabling much higher metal removal rates, better quality and longer tool life.

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.

Conditioning of the cutting edge, such as a honing or chamfering, to make it stronger and less susceptible to chipping. A chamfer is a bevel on the tool’s cutting edge; the angle is measured from the cutting face downward and generally varies from 25° to 45°. Honing is the process of rounding or blunting the cutting edge with abrasives, either manually or mechanically.

Making the hole is sometimes the easiest part of cross-hole drilling. “We have customers that once took 10 hours to deburr hydraulic manifolds filled with dozens of holes,” said Stan Kroll, sales manager at J.W. Done Corp., Hayward, Calif. “And with one slip of the blade, the part was scrapped.”

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.

Cermets also feature higher hot hardness than carbide, meaning they maintain more wear resistance at high temperatures. As a result, cutting speeds can often be increased with these tools without compromising tool life.

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

Mr. Pettay works for Kyocera Ceratip Cutting Tools (Mountain Home, North Carolina), a company offering inserts made of various materials—carbide, ceramic, cermet, CBN and PCD. He says an important thing to understand about cermets, relative to these other materials, is the extent to which cermets’ performance envelope has changed. The development of micrograin cermets has enhanced the tool material’s toughness. On the continuum of toughness versus wear resistance, cermets used to occupy a smaller spot close to ceramics. (See the illustration below.) Now, cermets stretch farther on this graph, bridging the performance gap between ceramics and the toughest carbides.

Cast aluminum is also a problematic metal. The problem here is mechanical rather than chemical, and the culprit is silicon. Cermets generally do perform well when machining aluminum, but the high silicon content of cast aluminum has an abrasive effect that can compromise the insert’s ability to produce a smooth finish.

This simple change to a Swiss-type turning machine’s toolpath can dramatically improve its ability to manage chips.

Kip Hanson is a contributing editor for Cutting Tool Engineering magazine. Contact him by phone at (520) 548-7328 or via e-mail at kip@kahmco.net.

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

Micrograin cermets offer improved toughness. Microscopic photography of one such cermet grade (above) shows what “micrograin” physically means.

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

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.

Fluid that reduces temperature buildup at the tool/workpiece interface during machining. Normally takes the form of a liquid such as soluble or chemical mixtures (semisynthetic, synthetic) but can be pressurized air or other gas. Because of water’s ability to absorb great quantities of heat, it is widely used as a coolant and vehicle for various cutting compounds, with the water-to-compound ratio varying with the machining task. See cutting fluid; semisynthetic cutting fluid; soluble-oil cutting fluid; synthetic cutting fluid.

2-D or 3-D path generated by program code or a CAM system and followed by tool when machining a part.

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.

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.

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

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.

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

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

When entering and exiting a cross-hole, Sandvik Coromant recommends reducing the feed to a quarter of the normal rate.

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

What Is A Cermet? The word cermet is a contraction of “ceramic” and “metal.” A cermet consists of a ceramic material (such as titanium carbide or titanium carbonitride) cemented with a metal binder. The ceramic provides the wear resistance, and the metal provides the toughness.

For the most part, though, Brown said spade drills are just the ticket for holes 3⁄4 " in diameter and larger. “It’s application-dependent, but we will typically go in with a spade drill, because most of the time with cross-hole drilling you’re talking about a deeper hole. Spade drills are more cost-effective than either indexable-insert or solid-carbide drills. We offer HSS and carbide spade bits. If you’re in a situation where there’s a lot of shock or inconsistency in the workpiece material, we’d recommend HSS because it absorbs shock a lot better than carbide. But if the shop has a good setup and productivity is important, you’ll be looking at a carbide tip.”

Applications Cermets are excellent at finishing. Beyond that, what other applications should prospective users consider?

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.

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

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

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.

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.

Combined variations of all dimensions of a workpiece, measured with an indicator, determined by rotating the part 360°.

Even simple cross-hole drilling presents challenges, including high tool wear, poor chip evacuation, difficult-to-remove burrs and tool deflection that can snap the toughest of drills. But there are ways to turn the bane of holemaking into a more bearable task.

The on-again, off-again nature of cross-hole drilling introduces yet another challenge. “Cross-holes are difficult from a programming standpoint,” said Product Specialist Nika Alex at Mitsubishi Materials USA Corp., Fountain Valley, Calif. “Because you’re constantly entering and exiting the workpiece, you have to speed up and slow down accordingly. And since most of these holes are quite deep, you’re working with a very long drill, which usually means using a short drill to get the hole started and switching to a longer one mid-cycle. That can mean vibration and flex until the tool is fully engaged—if so, try reducing speed momentarily.”

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.

Combined variations of all dimensions of a workpiece, measured with an indicator, determined by rotating the part 360°.

The amount of edge break is controlled by the preload on the tool together with simple programming techniques, providing anything from a sharp, burr-free edge to a large radius. “It’s just like milling a thread,” Kroll said. “We tell the tool the diameter of the hole and how deep to go. Orbitool takes care of the rest.”

Milling cutter held by its shank that cuts on its periphery and, if so configured, on its free end. Takes a variety of shapes (single- and double-end, roughing, ballnose and cup-end) and sizes (stub, medium, long and extra-long). Also comes with differing numbers of flutes.

Habben said this is just part of the story, though. “As the drill tip breaks through into the intersecting hole, a rule of thumb would be to decrease the feed rate by about 50 percent. This helps minimize the number of burrs and also to reduce deflection, especially in an off-center situation.”

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.

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

According to Liechti, the biggest problem with cross-hole drilling is when the holes are extremely off-center. “All our tools are carbide, so they’re fairly stiff, but if the two holes are very off-center to one another, there’s a risk of tool breakage,” he said. “In that case, we recommend going in with a wider point angle, almost like an endmill, to get the far side of the hole started.”

Stringy portions of material formed on workpiece edges during machining. Often sharp. Can be removed with hand files, abrasive wheels or belts, wire wheels, abrasive-fiber brushes, waterjet equipment or other methods.

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

Grooves and spaces in the body of a tool that permit chip removal from, and cutting-fluid application to, the point of cut.

A custom spade drill from Allied Tool offers long margins for additional support when cross-hole drilling.

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.

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

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.

Hans Liechti of Mikron Tools sees things differently. While he acknowledges the complexities of cross-hole drilling, Liechti said CAM software should have no problem calculating the proper toolpath. “It’s not as much of a big deal as it once was.”

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

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

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

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

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

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

On the other end of the spectrum are P-2 tool steel injection molds for complex medical devices, with more holes than a block of Swiss cheese and tolerances that make even veteran machinists weep.

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.

Drilling cross-holes in some parts is no big deal. These are often simple parts, such as aluminum valve bodies, where the holes aren’t too deep and meet on-center, and the customer can live with a small burr at the intersection.

Habben made a final point, one that machinists often overlook. TIR, or total indicator runout, should be less than 0.001 " and preferably better than 0.0005 "—a critical characteristic for improved tool life and hole accuracy. That might sound like a tall order to many shops, but Habben argued it is easily achieved with high-quality hydraulic or shrink-fit toolholders.

Included angle at the point of a twist drill or similar tool; for general-purpose tools, the point angle is typically 118°.

Chip evacuation is critical, according to Habben. “High-pressure coolant above 600 psi is recommended to flush those chips out. And when you get into larger holes, say, above 3⁄8" in diameter, it’s important to have a pump that can handle the increased volume. Figure on 5 to 10 gpm for ½ "-dia. holes and up to 15 to 20 gpm on larger holes. That will give you the volume needed to overcome the fluid loss when you break through into the cross-hole.”

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

Mastercam 2025 incorporates big advancements and small — all based on customer feedback and the company’s commitment to keeping its signature product best in class.

• Learn the cross-hole programming two-step, juggling feeds and speeds to keep holes straight and avoid broken cutting tools.

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

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.

Cermet Limitations Nickel is a common binder material for cermets. This creates the potential for a chemical reaction if the workpiece has high nickel content, too. (That is, the cermets' inertness doesn't apply if nickel is involved.) High-temperature alloys and some stainless steels are among the nickel-containing materials that can cause problems when using uncoated cermet tooling.

One possible cure is effective edge preparation on the drill, together with appropriate feed and speed modifications. “We usually recommend a corner clip in this case,” Habben said, “meaning a 45° chamfer on the outer margin of the drill, together with a small edge prep, say, a light T-land or a hone of around 0.003 " to 0.004 " on the cutting edge. And it’s especially important to use a sharp tool.”

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.

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.

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

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

No edge prep in the world, however, will help without a good drill. The cutting forces generated on breakthrough when cross-hole drilling can be tremendous, and deflection becomes a real problem. Al Zaitoon, sales and marketing manager for YG-1 Tool Co., Vernon Hills, Ill., explained that indexable-insert drills, or insert drills, a staple in most machine shops, are not the answer for cross-hole drilling.

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

Zaitoon painted this picture of a typical cross-hole. “Say you’re using a ½ " solid-carbide drill to go into a 3⁄8" cross-hole and it passes into another hole after that. The drill has a margin length of 2 " or maybe 3 ", so that helps stabilize it as it passes from one hole to the next. You don’t have that with a spade or insert drill. They end up just bouncing around.”

Mitsubishi says it through-coolant, solid-carbide, double-margin drill achieves optimal chip evacuation when cross-hole drilling.

Main body of a tool; the portion of a drill or similar end-held tool that fits into a collet, chuck or similar mounting device.

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.

Some additional items in the cross-hole drilling first-aid kit are advanced coatings and lots of coolant because the process can generate a lot of heat. “Coatings help, because many times in cross-hole drilling you’re running at a reduced feed rate, which means poor chip formation,” Habben said. He noted Sumitomo offers a polished, TiAlCr coating just a few microns thick. “It uses nano-coating technology, meaning the coating is applied in extremely thin layers. This makes it very lubricious and significantly less expensive than a diamond coating, while offering comparable tool life.”

Sumitomo’s Habben seconded Zaitoon. He suggested that insert drills are bad juju on cross-hole drilling and recommends solid-carbide and replaceable-tip drills instead. “Insert drills are not very good on cross-holes because they have a single effective cutting edge and tend to deflect,” he said.

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

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

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

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?

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

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

Combining the wear resistance with today’s enhanced toughness makes the case for cermets stronger. Mr. Pettay says certain misconceptions about cermets are even less accurate today, including the following:

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

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.

Also, examine the drilling sequence. “A lot of valve bodies use a porting tool for the valve seat, then a small cross-hole for the hydraulics, which is usually off-center. Correct processing of the part would be critical in this situation,” Habben said. “For example, the small-diameter holes for the hydraulics you would want to do first, and then go in with the porting tool after, because the larger tool is generally shorter and can handle the deflection better.”

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.

Available in two major types: tungsten high-speed steels (designated by letter T having tungsten as the principal alloying element) and molybdenum high-speed steels (designated by letter M having molybdenum as the principal alloying element). The type T high-speed steels containing cobalt have higher wear resistance and greater red (hot) hardness, withstanding cutting temperature up to 1,100º F (590º C). The type T steels are used to fabricate metalcutting tools (milling cutters, drills, reamers and taps), woodworking tools, various types of punches and dies, ball and roller bearings. The type M steels are used for cutting tools and various types of dies.

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.

In cases where this doesn’t quite cut the mustard, Brown recommends a special, where the body of the drill has guides to help stabilize it through the interruption.

Thermal shock presents an additional potential for danger. Coolant should be used only in continuous cutting applications where the coolant can remain on the cermet tool, such as finish turning and threading. Coolant should not be used for milling with cermets. Even in continuous cutting applications, says Mr. Pettay, coolant should be used only for cuts that do not exceed 0.010 ipr feed rate or 0.080 inch depth of cut.

Other limitations of cutting with cermet inserts relate to strength. Cermets today are tougher than they once were, but their toughness still does not match that of the toughest carbides. Cermets are not appropriate for roughing. Also, because bending strength is low, cermets require lower feed rates.

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

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.

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.

Liechti is manager of the cutting tool division at Mikron Corp. Monroe, Monroe, Conn., which specializes in tools smaller than 6mm in diameter. This means a lot of solid-carbide, coolant-fed drills as well as custom step tools, reamers and porting 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.

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Despite an unorthodox name, the Crazy Drill has all the requirements needed when it comes to cross-hole drilling, with a 140° drill tip, double-margin flutes and a coolant-fed, solid-carbide body. “You can be quite aggressive with these tools, up to five times the typical feed rate, then slow down as you break through into the cross-hole.”

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

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).

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

• A honed edge with a corner clip on the outer margin of the drill reduces burr formation and makes tools last longer.

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

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."

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.

Replaceable-tip drills have basically the same geometry as solid-carbide drills, with two effective cutting edges in a one-piece design. The head is secured with screws against a ground serration. This offers high locational accuracy as well as strength in the drive mechanism, according to Habben.

Ask Liechti which tool is best for cross-holes and he’ll probably say something crazy. “Our standard line of tools is called the Crazy Drill.” You can’t help but ask why. “We developed a special drill for a customer. When he came in for the runoff demo, we exceeded his expectation by two times. He said those tools cut like crazy.”

The combination is more chemically inert than tungsten carbide, Mr. Pettay says. The inertness means that edge buildup and crater wear are less likely. The result is not just improved tool life, but also an improved machined finish. One of the key benefits of cutting with a cermet edge is the ability to achieve a finish that may eliminate the need for polishing or grinding.

Habben added that for holes below ½ " in diameter, “solid carbide is the only way to go.” However, he warned, anything much larger than this and you could be talking serious cash, whereas a replaceable-tip drill is about half the cost and as accurate. Habben said: “A lot of cross-holes are deep, maybe 12 to 20 times diameter. With hole sizes running anywhere from 1⁄8" to 1 " or more, solid-carbide tools this long can get expensive, especially for large holes. You can easily spend $500 to $800 per drill.”

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.

The toughness of this material has improved. Today, the applications for cermet inserts go well beyond finishing.

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Despite the competitive nature of cutting tool manufacturers, there’s a lot of consensus on cross-hole drilling recommendations, and most companies agree with the following advice:

Kroll and J.W. Done President Michael Kapgan will tell you the Orbitool deburring device eliminates the craft factor of manual deburring. “You can literally do it with your eyes closed,” Kapgan said. “It greatly simplifies the manual deburring process. You just run it in and out of the hole, like you’re playing a violin.”

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

An aggressive cutting head (top) is rigidly clamped to a through-coolant drill shank on Sumitomo’s SMD-style replaceable-tip drill.

Flat end-cutting tool used to produce holes ranging from about 1" to 6" in diameter. Spade drills consist of an interchangeable cutting blade and a toolholder that has a slot into which the blade fits. In horizontal applications, universal spade drills can achieve extreme depth-to-diameter ratios, but, in vertical applications, the tools are limited by poor chip evacuation.

Matt Sippel, senior product application engineer at Melin Tool Co., Cleveland, agreed: “The one big thing we’ve been doing for cross-hole drilling is putting a special geometry on our coolant-fed drills. The tip tends to be a little bit flatter, say, around 140°, with a slight chamfer on the outside edge, and sometimes an edge prep. This is an old trick in the aerospace industry. It tends to protect the corner of the drill as you break through into the intersecting hole.”

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