Iscar is about to change metal cutting… again! - 90 degree carbide insert

Meanwhile, the advance of additive manufacturing could intensify focus on finishing and semi-finishing over roughing. Compared to carving out solid billets or blocks of material, machining 3D-printed, near-net-shapes requires different techniques and different cutting tools. “This means shifting to cutters that require less radial engagement but will move with more speed,” Mr. Apple says.

Turning machine capable of sawing, milling, grinding, gear-cutting, drilling, reaming, boring, threading, facing, chamfering, grooving, knurling, spinning, parting, necking, taper-cutting, and cam- and eccentric-cutting, as well as step- and straight-turning. Comes in a variety of forms, ranging from manual to semiautomatic to fully automatic, with major types being engine lathes, turning and contouring lathes, turret lathes and numerical-control lathes. The engine lathe consists of a headstock and spindle, tailstock, bed, carriage (complete with apron) and cross slides. Features include gear- (speed) and feed-selector levers, toolpost, compound rest, lead screw and reversing lead screw, threading dial and rapid-traverse lever. Special lathe types include through-the-spindle, camshaft and crankshaft, brake drum and rotor, spinning and gun-barrel machines. Toolroom and bench lathes are used for precision work; the former for tool-and-die work and similar tasks, the latter for small workpieces (instruments, watches), normally without a power feed. Models are typically designated according to their “swing,” or the largest-diameter workpiece that can be rotated; bed length, or the distance between centers; and horsepower generated. See turning machine.

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

Used to finish the surface of many automotive components — including camshaft lobes and journals; crankshaft mains, pins, thrust walls and oil seals; and transmission shafts — Norton Finium is wound onto a roll that varies in length depending on the machine being used. The width of the film depends on the part being polished. A user places the film over polishing shoes attached to polishing arms while the part is secured in a fixture and the polishing arms are clamped around the part. The array keeps contact with the part and Norton Finium for a given amount of time, generating the desired finish.

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

In the past, deburring was treated as an afterthought in the automotive industry. The focus always had been on more efficiently making parts and vehicles, but nowadays manufacturers review costs and work hours for all aspects of production. And manual deburring is time-intensive and subject to human error.

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.

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.

When it comes to automotive parts and systems, it could be said that it’s not so much how you start but how you finish.

This is not to suggest that titanium turning is the only potential application of binderless CBN, nor that milling or other interrupted cutting is out of the question. On the contrary, Sumitomo reports that the inserts have been applied successfully in interrupted cuts in both powder metal and cast iron, as well as hardened steel milling in certain conditions. Meanwhile, development continues on different edge geometries and CBN particle-size formulations that add strength and toughness. The tools have also been been applied to turn medical parts from such materials as cemented carbide and cobalt chrome (Co Cr).

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

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

Modern Machine Shop is the leading publication and media brand in North America devoted to CNC machining. MMS combines unprecedented editorial access to manufacturing facilities with decades of experience to provide long-form content that is both insightful and impactful. About Us

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

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

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.

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.

Finishing operation in which a loose, fine-grain abrasive in a liquid medium abrades material. Extremely accurate process that corrects minor shape imperfections, refines surface finishes and produces a close fit between mating surfaces.

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

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

The cutting method is fairly traditional using a carbide rotary burr, but Orbitool features the combination of a flexible drive shaft made of tool steel, a carbide shaped cutter and a polished steel disk. This commonly is referred to as a lollipop cutter. The larger-diameter polished disk negates the risk of damage to a part.

Tool that cuts a sloped depression at the top of a hole to permit a screw head or other object to rest flush with the surface of the workpiece.

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

In devising its hard-turning strategy, this die/mold shop has been able to speed the production of its new deep-draw round tooling offerings by turning them instead of grinding them after heat treating.

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.

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

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.

“Improving those cross-holes gets us one step closer to increased reliability,” Kroll said. “Higher-quality reliable parts made economically and quickly is the goal.”

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

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.

Heidi Bethel is a freelance writer who spent several years writing technical pieces about manufacturing, operations and systems while working for an international geothermal company. She can be reached at bethelcommunicationandevents@gmail.com.

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.

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

The binderless CBN insert ran for more than 7 hours before chip control began to noticeably degrade. Photo Credit: OMIC

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

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.

The two flat, parallel horizontal lines represent surface finish (gray) and insert wear (blue) with the carbide insert after 45 minutes of machining at 200 sfm. The vertical blue bars indicate the progression of binderless CBN insert wear over time at both 400 SFM (light blue) and 600 SFM (dark blue). The second pair of horizontal gray bars show surface finish deterioration over time with binderless CBN at 400 SFM (light gray) and 600 SFM (dark gray). Photo Credit: OMIC

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

“The original idea for the Orbitool came about specifically for aerospace fittings because of the difficult nature of their intersections and radius requirements,” Kroll said. “But it was applicable to one of our earliest customers, which was Ford, using it on camshafts.”

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

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.

Urmaze Naterwalla, OMIC head of R&D, analogizes traditional, “bindered” inserts to a road, with the individual particles embedded in the surface representing the cutting material (CBN in this case) and the tar representing the binding material. The binding material is softer, so it breaks down first as the surface deteriorates. It tears away in chunks to leave potholes. Without the tar, the particles are fused directly to one another. There are no potholes because the surface wears away at a relatively constant and predictable rate, resulting in two parallel divets carved from the wheels of passing traffic.

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

Testing continued. Pushed to 600 sfm – three times the speed of carbide – the binderless CBN lasted more than 400 minutes before exhibiting the same level of flank wear as the carbide insert at 45 minutes (although with CBN, surface roughness had reached nearly 65 Ra by the 400-minute mark). At the 435-minute mark, chips began to become progressively long and stringy. Finally, at 555 minutes, the insert tip wore into a crescent shape, “much like sanding a block of wood down on a belt sander,” says Cody Apple, machining solutions researcher at OMIC. “This was predictable and easy to detect when it occurred.”

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.

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

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

The company has developed two new tools to support Y-axis turning: CoroTurn Prime and the CoroPlex YT twin-tool.

The higher-temperature, higher-pressure sintering process that makes binderless construction possible is significant for more than just machining performance. Cobalt, a critical ingredient in the “cement” that holds cemented tungsten carbide together, is increasingly rare and costly. The case is the same for tungsten, Niobium and other elements of these inserts. Eliminating the need for these materials in a cutting tool eliminates the need to pull them from the Earth, thus preserving precious resources while benefitting the environment as well as people directly affected by the mining.

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

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.

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

DeBurr-Z can be used for engraving, allowing a quicker approach to the workpiece and the ability to mark on curved surfaces.

The biggest difference was speed. In repeated testing, all three CBN geometries ran at 400 sfm, versus only 200 sfm for the cemented carbide. Nonetheless, OMIC was not finished. Researchers pushed the highest-performing CBN insert (with the medium rake angle) well past the 45-minute mark, and they extended periodic wear measurements from 15- to 30-minute intervals. After 230 minutes, chips were virtually indistinguishable from those generated at the 45-minute mark. In contrast, the carbide insert had worn twice as much, was removing only half the material, and was leaving a rougher surface.

“Polishing is a rubbing or abrasion process where the cutting fluid (mineral seal oil or polishing oil), the Finium abrasive and resin from the bond form a flurry, and that’s what’s doing the finishing,” Goetz said. “Typically, we’re only taking off between 3 and 5 μm when we’re lapping. By polishing, you get a better surface condition and the engine runs more true. In turn, it cuts down on the vibration and noise and adds to the life of the product.”

The finish-turning tests were conducted at the Oregon Manufacturing Innovation Center (OMIC), a nonprofit collaborative research organization near Portland, at the request of the inserts’ developer, Sumitomo Electric Carbide, Inc. OMIC ran three NCB100 binderless CBN turning inserts against the AC51015S cemented carbide grade that Sumitomo would otherwise have recommended for the application. As expected, the carbide performed well in repeated tests, exhibiting 0.00208 inch of tip wear after 45 minutes in the cut. “There were no anomalies to note during these trials,” reads an OMIC report on the tests. “The insert showed even and predictable wear over time, creating a great baseline to compare from.”

Compared to carbide, the binderless CBN ran three times faster, removed nine times the material and lasted 3 times longer on a single cutting edge.

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.

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.

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."

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.

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.

The PSZ Turn System offers products for front-turning, grooving, thread-cutting and back-turning applications. Additionally, the MEFF Chipbreaker enables excellent chip control, low cutting force and good surface finish at a range of depth of cuts.

Research also continues into other binderless formulations. In fact, Sumitomo first applied its new direct conversion sintering process for binderless polycrystalline diamond (PCD), which is useful for machining tungsten carbide drawing dies and wear plates as well as ceramic materials. The company expects applications for these tools, and potentially others, to expand along with demand for new, highly durable yet difficult-to-machine materials for spacecraft, aircraft, automobiles, medical and electronic components and more. “We should recognize that there’s going to be an evolution, just like there was with carbide,” Mr. Naterwalla says. “The more we adapt to what this is capable of, the more that evolution will move forward.”

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.

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

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 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."

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.

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.

Heidenhain and Acu-Rite Solutions are offering several hands-on experiences at their booth this year, as well as internal components that reduce energy use.

In 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

Although carbide inserts are proven performers in virtually all types of CNC machining, aerospace alloy finishing presents a particularly good opportunity to start exploring alternatives. In recent testing, a new type of cubic boron nitride (CBN) finish-turning insert ran three times faster, lasted three times longer and removed nine times the material as cemented carbide in titanium 6AL-4V, all on the same cutting edge. “Consistent chip control and a long-lasting edge make this a great candidate to replace current stable finishing processes using carbide,” the researchers wrote.

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

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

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).

Yet, binder can do more than just hold insert material together. Jason Miller, a national applications engineer with Sumitomo at the time of this writing, says it also acts much like an automobile suspension, which employs springs and other shock absorbers to smooth the ride. In fact, specially formulated binders help other CBN inserts withstand the forces associated with gear machining and other interrupted-cutting applications that are hard on tooling. Applying the new binderless inserts for such work would be “akin to applying a drag car to drive over a mountain,” he says. “It doesn’t work.”

The extent of these broader benefits depends on the extent to which performance benefits and economies of scale drive the expansion of binderless CBN (and perhaps other varieties of binderless insert) into new applications and materials. Meanwhile, the new NCB100 binderless CBN offering provides a ready alternative for work that otherwise would require redundant tooling and/or accounting for insert changes, wear-offset entry and the risk of tool breakage during lengthy, automated machining cycles.

The mathematical expression denoting one of several parameters that describe surface texture (same as average roughness Ra). Average roughness is the arithmetic average height deviation of the measured surface profile from the profile centerline. See surface texture.

“The flexible shaft allows us to bend and pre-load the tool,” Kroll said. “We have a protective ring to place against the wall, bend the shaft slightly and pre-load the cutting tool. The toolpath uses helical interpolation, otherwise known as a thread spiral or helix spiral. With the Orbitool, the operator doesn’t have to program any complex contours or even know precisely where their edge is or its precise shape. We pre-load the tool and place the helix spiral where deburring is needed. It’s the tool’s ability to self-select and constantly bend and flex to the environment around it that allows it to deal with an interrupted cut. It only cuts material in the area where you need deburring but won’t damage anywhere else.”

“When you’re talking about bearing surfaces on a crankshaft or camshaft, even at a fine Ra there is wear on the shaft and bearings,” said David Goetz, senior application engineer at Norton | Saint-Gobain Abrasives in Worcester, Massachusetts. “Although it may be slight, all that metal ends up in the engine.”

From the standpoint of quality, automakers can track engine failures to the tiniest burr in a camshaft. With possibly thousands of complex parts, an engine can be affected by one particular cross-hole shaving that enters a timing system and can cause the entire engine to fail.

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.

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

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

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

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.

“We’ve realized that many shops weren’t factoring in the cost of someone in the deburring department manually damaging or scraping the parts,” said Stan Kroll, partner and general manager of J.W. Done Corp. in Hayward, California. “There were cases where thousands of engine blocks weren’t deburred properly and now they have to go back to fix them. That gets costly very quick.”

When it comes to surface condition, smoothness really matters. Ra, or the arithmetic average of surface heights measured across a surface, gives a snapshot of the microscopic peaks and valleys on any given part.

Traditional deburring methods include using abrasive brushes, reamers and carbide balls attached to a grinder, with an operator going after every hole to remove extra material. Some dedicated deburring tools, such as J.W. Done’s Orbitool, are designed strictly for cross-drilled hole deburring. The tool is used just like any cutting tool found on a lathe turret or a tool magazine of a CNC or milling machine. Orbitool expressly removes burrs from the intersection of cross-holes. The operation can be tailored to leave a minimally broken edge or a blended radius.

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!

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.

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.

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

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.

With the many complicated components in an automotive system, one tiny burr, misplaced fit, chip, ding or uneven finish can wreak havoc and affect the performance of the entire engine. The industry looks for perfection down to the micromillimeter, and that’s where technology for finishing comes in. Products exist to tackle various aspects of automotive finishing, including Norton Finium, Orbitool and DeBurr-Z.

A high-pressure, high-temperature sintering process enables fusing submicron-size grains of CBN together without binder to maximize hardness, thermal conductivity and the resulting advantages in titanium and cobalt chrome. Photo Credit: Sumitomo Electric Carbide, Inc.

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

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.

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.

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

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.

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

Two of the CBN inserts, one with a low rake angle and one with a high rake angle, experienced similar levels of tip wear after 45 minutes (0.0024 inch for both CBN geometries). At this point, the carbide insert required indexing to maintain chip control. However, both CBN inserts continued to produce short, tightly curled chips. A third binderless CBN insert, this one with a medium rake angle, performed even better, wearing only half as much (0.0012 inch) at the 45-minute mark.

A new formulation of cubic boron nitride could provide a more solid alternative to cemented carbide as finish-machining becomes more demanding.

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.

The design freedom of additive manufacturing delivers increased performance to cutting tools. At the world’s leading exposition for machine tools, I saw various examples of this.

Turning this titanium tube provided a consistent baseline for the insert comparison. Photo Credit: OMIC

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

The binder in most CBN inserts can act like a shock absorber, but only at the expense of some of CBN’s natural advantages. Photo Credit: Sumitomo Electric Carbide, Inc.

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.

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

Norton Finium microfinishing films use a proprietary resin system to hold grains in place for finishing in automotive engine applications. The film-backed ultrafine grit abrasives come in a range of shapes, sizes and grits to fit a wide variety of requirements and eliminate the concern of grain fallout, which could leave coarse scratches and result in defective parts.

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.

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.

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.

Nonetheless, a drag car is ideal for rocketing down a perfectly smooth road. And for binderless CBN, the continuous surfaces of titanium aerospace parts like the ones machined at OMIC are essentially racetracks. Interruptions are rare, and cutting depths are shallow, recommended at only 0.020 inch in titanium.

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.

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?

Runs endmills and arbor-mounted milling cutters. Features include a head with a spindle that drives the cutters; a column, knee and table that provide motion in the three Cartesian axes; and a base that supports the components and houses the cutting-fluid pump and reservoir. The work is mounted on the table and fed into the rotating cutter or endmill to accomplish the milling steps; vertical milling machines also feed endmills into the work by means of a spindle-mounted quill. Models range from small manual machines to big bed-type and duplex mills. All take one of three basic forms: vertical, horizontal or convertible horizontal/vertical. Vertical machines may be knee-type (the table is mounted on a knee that can be elevated) or bed-type (the table is securely supported and only moves horizontally). In general, horizontal machines are bigger and more powerful, while vertical machines are lighter but more versatile and easier to set up and operate.

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

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

Other deburring tools exist to help with the top and underside edges. Tapmatic Corp. in Post Falls, Idaho, created DeBurr-Z, which works on a CNC machine for both compression and extension, allowing the cutting tool to follow the outer contours of the component. With an adjustable force, the pressure may be increased or decreased to accommodate the type of material and the desired edge break.

Liquid used to improve workpiece machinability, enhance tool life, flush out chips and machining debris, and cool the workpiece and tool. Three basic types are: straight oils; soluble oils, which emulsify in water; and synthetic fluids, which are water-based chemical solutions having no oil. See coolant; semisynthetic cutting fluid; soluble-oil cutting fluid; synthetic cutting fluid.

Cutting tool repeatedly enters and exits the work. Subjects tool to shock loading, making tool toughness, impact strength and flexibility vital. Closely associated with milling operations. See shock loading.

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

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.

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.

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.

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.

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

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

The primary difference between this CBN and other inserts is not what it contains, but what it lacks: a binder to hold the sintered material together. Rather, the nanoparticles are fused directly to one another to form a virtually solid, continuous cutting surface. This construction enables taking full advantage of CBN’s extreme hardness and thermal conductivity in a material that is notorious for work hardening.

“They can machine the parts faster and better,” Kroll said, “but deburring and finishing is the last step. It may not be the most important, but it’s still a step you can’t skip. There will always be a finishing process required on the part after the machine but before its final destination. It’s the last, most important step before anything ships out in a sellable condition.”

At 400 sfm (twice the speed of carbide) and 230 minutes in the cut, the binderless CBN insert was still performing consistently. The carbide insert required indexing at the 45-minute mark. Photo Credit: OMIC.

Process of generating a sufficient number of positioning commands for the servomotors driving the machine tool so the path of the tool closely approximates the ideal path. See CNC, computer numerical control; NC, numerical control.

“If you have a part number, logo, date or batch code, you can use it to mark the workpiece,” Johnson said. “The advantage of having the axial compression for engraving is it allows you to approach the workpiece faster and makes the engraving process quicker than it would be if you held the engraving tool in a solid holder. We also offer a ScribeWriter, which is a scribing tool; our TapWriter for dot peen marking, creating dots on the workpiece; and we offer our Marking Head for stamping the workpiece. It uses custom stamps or standard type to mark numbers, date codes and other information.”

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

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

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

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

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

The new SG66 carbide grade is suitable for reliably processing highly temperature-resistant and other difficult-to-machine steel alloys.

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

Chamfering holes on a curved surface also presents problems for conventional deburring methods. Using a standard countersink tool results in inconsistent edge breaks. Going around the holes with the axially floating DeBurr-Z produces consistent results, said President Mark Johnson. In general, either angular- or spherical-shaped burr cutting tools are used to apply the right contact to the workpiece for chamfering or deburring the edge.

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.

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

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

“The edges of the workpiece can often be a little difficult to identify or clearly define like in the case of castings, cross-holes or slots,” he said. “It can be difficult to follow the edges evenly, but a floating tool has the compensation that lets the burr cutting tool follow the edge even when its position varies.”

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

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.