“This approach can be a big problem when you are dealing with a 0.0001-inch tolerance,” Mr. Anthony points out. “These manual interventions, in addition to being very time-consuming, open the door for human error that can inadvertently introduce the very process imperfections that the optional stop was intended to prevent,” he concludes.

It also became clear that entering the correct values for the variables with which this software needed to work could not be based on guesswork. “That’s when the R&D project started to really look like R&D. We set out to develop our own calculator to generate those values, based on tables of results gathered from test cuts on each machine, using different materials and different styles of cutters,” he says.

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.

Mr. Anthony summarizes some of the other findings or observations that have come out of this intense research on Dynamic Motion:

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

The focus of this research centered on determining what chip load was the most productive yet safest for each combination of cutting tool and machining center. Generating the tool paths and corresponding depths of cut and feed rates to maintain that target chip load was taken care of by the software. Following is a summary of the theory behind what Mr. Anthony was up to in this research.

High quality precision cutting tools for front and back deburring, chamfering, drilling, countersinking, counterboring and back spotfacing in one operation.

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.

These optional stops were costly. Because machinists usually tend more than one machine at a time, dealing with a machine in the M01 mode may not happen promptly. Likewise, resolving the issue behind the stoppage can mean a lengthy delay. Checking a workpiece dimension or the condition of a cutting tool may involve several steps requiring cautious judgment about a decision to recut or not, or move the part to the CMM for inspection, and then setting it back up on the machine.

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

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

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Finally, Mr. Anthony likes to hint about some insights and discoveries resulting from ADEX’s R&D programs that he now considers essential secrets to the shop’s success. But his invitation to other shops is to follow ADEX’s lead on a similar path to make their own discoveries and develop their own competitive advantages: “We’ve found ours and have more to come. Be inspired to go out and find yours.”

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

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

One of the things Mr. Anthony learned from an earlier stint with a large aerospace firm in his home state of Georgia was the importance of exploring new technology and giving it a try—not when this technology had become safe, easy and was in everybody’s shop, but while it was still taking shape, proving itself and finding direction. Although this former employer had the resources to engage in an R&D program on a large scale, Mr. Anthony recognized that the concept could be pursued in a company the size of ADEX as well. It did not have to be a formal program with a rigid time frame, but could follow a freer approach based on an ongoing commitment to devoting as much available time as possible to a specific goal or targeted benefit.

Naturally, spindle speed and feed rate are limited by the capability of the machine; faster spindles and more powerful axis drives can do a better job of producing thin chips rapidly, thus compensating for both lower metal-removal capacity and the lower heat-removal capacity of the chip.

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ADEX’s venturesome entrepreneurial spirit can be traced to its startup in 2007 as a shop specializing in five-axis machining. The founders, who have since moved on to other ventures, wanted to make the leap to advanced machining in a single bound. When Mr. Anthony joined the company in 2012, he brought with him almost 25 years of experience in CNC machining (including 10 years in five-axis machining), plus a background in process engineering and operations management. He was familiar with the other manufacturing technology in place at ADEX, which includes vertical turning, wire EDM, CAD/CAM and a computerized coordinate measuring machine. Mr. Anthony’s prior experience also involved a solid grasp of lean manufacturing and Six Sigma process improvement.

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

ADEX’s Charles Anthony and Chris Kozell, a Mastercam strategic accounts specialist with CNC Software, discuss some of the features of an aluminum landing gear component, which is machined on one of the shop’s five-axis Variaxis machining centers from Mazak.

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Constant-chip-load machining produces chips that are consistently alike in size and shape—usually long, lightweight shavings that look like tightly wrapped foil. Because roughing parts from solid billets can generate high volumes of chips, the consistently skinny shape of the chips aids in evacuation and prevents clogs in the chip conveyor.

This part is a good example of tool paths prepared with the Dynamic Motion option for certain roughing and finishing operations. Several critical part features, including all eight bored holes, must be within 0.001-inch true position to one another.

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To maintain a targeted chip thickness, smaller step-overs require a higher feed rate, but can yield higher metal removal. Dynamic Motion applies this rule as it generates a kind of trochoidal tool path within boundaries defined by part geometry.

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ADEX has found that the software enables the shop to use smaller, less expensive carbide cutters for more economical metal removal. “Sometimes part processing is more profitable when you are not trying to maximize metal-removal rates,” Mr. Anthony notes. Plowing through material as fast as you can is rarely the smartest strategy, he says.

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“Early on, we learned that Dynamic Motion was designed to create tool paths that resulted in parameters assuring a constant chip load on the cutter. The chip load that it keeps constant, however, is a value that tends to favor high feed rates and small stepovers, but maximizes metal removal. The idea is to take light cuts very rapidly under conditions that are best for the particular cutting tool and machine tool,” Mr. Anthony explains. He adds that there is a lot more to what Dynamic Motion does when generating a tool path, but constant chip load is a basic principle underlying its algorithms.

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

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.

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At this point, ADEX embarked on a one-year R&D project to apply this technology across the aerospace, defense and energy facets of the business. “We envisioned the potentially enormous benefits of in-process gaging and made it a priority. We also enlisted our Mastercam reseller, Barefoot CNC, as a partner in this project,” Mr. Anthony says. The reseller co-developed and installed a postprocessor for the add-on while soliciting substantial programming and testing support from Mastercam’s Manufacturing Lab in Tolland, Connecticut. The reseller also trained the CNC programmers and machinists in appropriate use of the add-on and postprocessor.

Mr. Anthony checks a comparison of inspection results from the on-machine probing and the shop’s coordinate measuring machine (CMM). Spindle-probe measurements (in blue) and CMM measurements (in gold) vary by no more than 0.0005 inch, ensuring that machining operations can be reliably verified in process using automatic probing in the lights-out mode.

Mr. Anthony notes that cutting with the full length of a milling cutter economizes tool usage. This is another benefit of constant-chip-load machining.

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

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

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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.

What Mr. Anthony calls constant-chip-load machining is one of the most important principles that underlies the Dynamic Motion option for generating tool paths in CNC Software’s Mastercam CAD/CAM software. Because ADEX has taken the time and effort to thoroughly master how to apply this option for best effect when programming complex parts in titanium and other super alloys, it has provided significant improvements in productivity and tool life across a range of workpiece types involving almost every machine tool in the shop.

“We routinely see tool life last two times longer and sometimes as much as five times longer, and we know our tool paths will protect the tool and part from damaging conditions experienced with other conventional types of tool paths,” he says. Of even greater benefit are substantial reductions in cycle times. “We usually get 20- to 40-percent higher metal-removal rates, especially during roughing, because the tool paths use the full potential of a cutting tool very efficiently,” he adds. Plus, good tool paths have helped ADEX successfully machine complex workpieces to tight tolerances in difficult-to-machine materials, because consistent, precise results in roughing using this programming option virtually ensure error-free finishing operations (which may also benefit from using this programming option.)

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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 company benefits, for sure, but so do shop employees, because they develop new skills, work more closely as a team and increase their earning power, he says.

It’s not just about constant chip load. The software calculates changes in material conditions during the metal-removal process to adjust step-overs based on remaining material, and even feed rates for microlifts designed to avoid dragging. This stock awareness is critical to keeping tool paths safe yet productive.

Of course, ADEX’s R&D program has not been restricted to making the most of techniques such as constant-chip-load machining. Establishing a practical approach to automatic and reliable on-machine probing for lights-out operation is another example. “All of these R&D efforts hinge on the same principles. We seek out new ideas, learn as much as we can, develop creative ways to apply them, and try to discover new and different directions that go beyond what other shops are likely to do. This is the only way to stay ahead of the pack,” Mr. Anthony concludes.

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Tolerance. Tolerance grade. Tolerance of a basic size for specific tolerance grade. 0. -25. H8. Minimum clearance. Recommended fits. 0.025. H8/f7. 0.089. Hole ...

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

Each tool setting technique has merit, and it depends on where you are as a shop and the type of work you do, as cost and efficiency all come into play.

In fact, the results were so promising that Mr. Anthony made a commitment to finding out as much as he could about this option and how it could be applied to the most challenging workpieces for which ADEX customers were requesting bids. This R&D effort would stretch over the next two years. “We were never not working on the application of this toolpath strategy. It became a habit to look at what applying this option would give us whenever roughing operations were a deciding factor in how to process a part,” Mr. Anthony says.

As the demand for faster production cycles continues to grow, the ability to produce high-quality parts quickly and efficiently has become increasingly important. High-speed 3D printing has emerged as a key solution to reduce lead times and increase productivity across industries. However, like any advanced technology, it comes with its own set of challenges. In this webinar, Forward AM will explore both the opportunities and hurdles of adopting high-speed printing with a particular focus on overcoming those challenges. It’ll start by discussing the fundamentals of high-speed 3D printing and how it differs from conventional 3D printing methods. It’ll then move on to the key factors that influence successful implementation, including the impact of materials, equipment and design considerations. One of the main hurdles in high-speed 3D printing is ensuring the right balance between speed and part quality. Different materials behave differently under high-speed conditions — and not all equipment is optimized for this process. Forward AM will showcase some validated materials and equipment that are proven to perform well under these conditions. In addition, the presenters will look at real-world examples and applications where high-speed 3D printing has been successfully implemented, highlighting the collaboration between designers, engineers and manufacturers. By the end of this webinar, you'll not only have a clearer understanding of high-speed 3D printing with FFF but also the practical steps and considerations needed to make the most of this cutting-edge technology. Agenda:  Introduction The power of high-speed printing Know the process The practical side

CNC programmer Dean Shaffer-Johnson studies a simulation of the tool paths used to machine a structural component for a commercial airliner. The finished aluminum part on his desk shows the thin walls for which constant-chip-load machining is especially beneficial because it avoids heat-induced warpage. The walls and floor of the pockets are about 0.080 inch thick.

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

The impetus to forge ahead with in-process gaging emerged several years ago when ADEX launched a comprehensive time-study analysis of its manufacturing processes. One of the results was particularly startling. The shop was consistently losing 15 to 50 percent of available production time because machines were paused in the M01 (optional stop) condition. “ADEX makes both large and medium-sized close-tolerance parts, ranging in value from $5,000 to $150,000. Our CNC programmers insert M01 codes into their programs, instructing and requiring machinists to inspect the part and cutting tool to ensure everything is OK and that we are not drifting into conditions that could result in scrap,” Mr. Anthony explains.

Only the play of light on the surface of this titanium aerospace part can reveal the telltale tool marks created by the programmed paths of the milling cutter. The apparent patterns reflect the motions that maintain a constant chip load on the cutting tool and follow other rules applied by the CAM software. This part weighed about 70 pounds before machining, but only 17 when completed

In 2014, when CNC Software introduced the Productivity Plus add-on for Mastercam, ADEX acquired it right away and began experimenting with it. This add-on enables the CAM programmer to create and call up Renishaw probing macros within the Mastercam programming session. At first, the initial release of the add-on proved somewhat difficult to apply on ADEX’s complex machining centers. Subsequent releases of the programming software and the add-on resolved these snags, however. The shop soon established a goal of implementing it on all of its Mazak five-axis machining centers for complex machining operations, as well as on its three-axis mills and large VTL.

Dynamic Motion is not always the best option. A traditional contouring tool path may be more than adequate when roughing operations are not a substantial portion of the process plan. Near-net -shaped forgings and pockets with irregular geometry are examples. “But we always look at the results as if we had applied the algorithm. At the least, it’s a useful learning experience, a valuable experiment,” Mr. Anthony notes.

The long, skinny chips produced by constant-chip-load machining can be easily flushed from the workzone and are less likely to clog the chip conveyor.

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

This combination of practical experience and theoretical knowledge helped Mr. Anthony give ADEX a firmer footing on its path to steady growth as a business, along with more certain achievement of its ambitious goals for technical excellence. Under his leadership, however, the mission of the company remains the same, that is, to apply advanced manufacturing technology to the 24/7 production of complex aerospace, defense and energy components consisting of superalloys such as Inconel, titanium, and other high-nickel or cobalt-based materials. “Because we approach every job with the standards and discipline expected of aerospace work, we’re perfectly comfortable being called an aerospace company, although about 35 percent of our revenue comes from outside this industry. Our biggest customer does build airplanes, however,” he says.

With its in-house R&D program, this aerospace shop seeks to be a leader, not a follower, on the path to innovation in advanced manufacturing. Finding and embracing a better way to generate tool paths for highly efficient and economical metal removal is a prime example of the value of this program.

MGS are renowned for being one of the Uk's leading tungsten machining companies. We offer both raw supply and heavy metal alloy engineering.

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The solution ADEX first envisioned was to use the spindle probes on its five-axis machines to measure parts at specified points during machining to verify that dimensions are not drifting out of specification and to adjust tool offsets to compensate without interrupting the manufacturing process. However, the shop found this approach impractical at first. It required the CNC programmer to be well-versed in metrology or to work with a measurement system programmer to develop in-process gaging routines.

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

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

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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

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

2021622 — Harvey Diamond ... The legendary jazz pianist Harvey Diamond has graced the Boston area for decades with his music which is at once both deeply ...

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

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

Another important fact is that the metal-cutting/chip-making process always creates heat. Most of this heat is localized in the chip itself, but the workpiece and the cutting tool may absorb some of it. Thicker chips can carry off more heat than thinner chips simply because thicker chips have more mass to hold the heat. When thinner chips are being produced, producing them faster by increasing the rotational speed of the cutter and/or the forward motion (feed rate) of the cutter in the direction of the cut can prevent heat from being transferred to the workpiece or cutter. This prevents them from reaching a damaging temperature.

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Working closely with customers and making careful investments has enabled this Wisconsin machine shop to tackle difficult jobs with tight deadlines as a core part of its business.

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

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

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.

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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.

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.

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

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

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The software keeps a cutter out of contact with the workpiece when the cutter is not actively cutting chips. For example, when the cutter is circling back to re-engage the workpiece, the Z axis is programmed to lift the tool off the floor of a pocket by 0.001 to 0.010 inch. These so-called microlifts prevent frictional rubbing that can heat and warp thin-floored workpieces as well as dull the bottom of the cutting tool.

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“We’ve just taken this homework to a higher level so that our calculator gives us a big head start in applying constant-chip-load machining very effectively,” Mr. Anthony says. “We can use the calculator to check different input values to see which combination gives us the most productive chip-load value.” He considers Dynamic Motion a tool to leverage the cutter technology that is out there today. For this reason, the shop is always looking for new products from cutting tool developers, as well as continuing to learn more about the performance of the machines in the shop.

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

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?

One of the first opportunities to take this approach arose when ADEX was introduced to the Dynamic Motion option in Mastercam by a programmer who joined the staff a few years ago. He had used this software feature to program the roughing operations for an aircraft bulkhead, thus bringing the cycle time down from 30 hours to 13. This report certainly got the attention of Mr. Anthony and his small group of programmers. Especially encouraging was news that the thin floor and thin walls of this bulkhead did not undergo any of the warping that can occur when machining forces create stress or heat from aggressive metal-removal processes.

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

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.

In October 2015, the five-axis machining programs with in-process gaging were proven to the overwhelming satisfaction of customers on three of the five-axis Mazak machines, Mr. Anthony reports. “In one particular case, 75 percent of process downtime has been eliminated by automating in-process gaging,” he says. He estimates there will be a 25- to 40-percent improvement in productivity, as well as 100-percent product acceptance as in-process gaging is implemented on many of the component details and assemblies running across all of the shop’s machine tools.

“With constant-chip-load machining, we can effectively machine titanium on our older machining centers that are not as powerful, rigid or as accurate as our five-axis machining centers,” Mr. Anthony says. This is possible because the chip-load values entered for these machines take these characteristics into account. “We get a safe tool path, and even if productivity is not as high, we can have roughing operations completed by the time the five-axis machines are available for finish machining. This frees up our most valuable machining assets for the most critical, close-tolerance work,” he adds.

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

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

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

“A better understanding of the cutting tools we use and how our machine tools behave helped us get more out of this approach to generating tool paths,” Mr. Anthony says. This knowledge was essential to determining the precise chip-load values that the Dynamic Motion option needs as input to create the rather unusual tool paths that deliver what Mr. Anthony has found to be very productive results.

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

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

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

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

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

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.

Toolpath simulation is essential. Mr. Anthony prefers the simulation feature in Mastercam to third-party simulation software because it is fast, highly detailed and very accurate. “Simulation gives us the confidence to hit the start button without worries and without time wasted dry-running a program on the shop floor,” he says. However, he cautions that no matter how good the simulation is, the user needs a trained eye to look for subtle things that can be a problem when chips, not pixels, are starting to fly.

To be clear, Dynamic Motion applies many other rules to toolpath generation in addition to maintaining a constant chip load, but following this principle is probably its greatest departure from traditional approaches, including those based on constant cutter engagement. “Mastering the concept of constant-chip-load machining was the key to unlocking its full potential at ADEX,” Mr. Anthony explains.

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On-machine probing is another requirement for leveraging constant-chip-load machining, because it enables roughing operations to proceed directly to finishing operations without interruption. “After roughing the part, we can probe the workpiece and automatically adjust tool offsets for finishing operations,” Mr. Anthony explains. But getting to the point where this approach was effective and reliable was neither simple nor quick. In fact, CAM-driven in-process gaging became another major (and highly successful) R&D project for ADEX.

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

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

Of course, making thick chips removes more material than making thin chips at the same rate. However, there are many reasons why making thick chips may be less desirable than making thin chips. For example, the cutting tool may not have the strength, sharpness and other characteristics to cut at its full radius. In that case, thinner chips will have to do.

MachineMetrics uses data synchronization and real-time monitoring of production to help keep schedules current and to reflect actual shopfloor conditions.

The stepovers and stepdowns called out values that departed from usual practice in roughing. The stepovers were usually well below the radius of the tool. Stepdowns were allowed to be the full length of the cutting flute on a carbide milling cutter—another reason to raise eyebrows. In addition, feed rates and spindle speeds calculated by the software were startlingly high. “We were almost afraid to take these programs out to the shop floor at first,” Mr. Anthony recalls. However, the test cuts consistently showed very positive results.

Then there is the hardness and other properties of the workpiece material to consider. Spindle speed, feed rates, depth of cut (stepover) and all of the other machining parameters have to be adjusted accordingly. Finding the right numbers for calculating the best machine settings became the goal for ADEX’s constant-chip-load research project.

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In Mastercam CAD/CAM software, the Dynamic Motion programming option enables the user to enter specific values for the machining parameters that will govern its unusual toolpath algorithms. These algorithms include provisions for maintaining a constant chip load, a machining strategy that ADEX cites as highly efficient in metal removal while prolonging tool life. Determining the best input values for this shop’s mix of machining centers and preferred cutter styles was the focus of one of its major R&D projects.

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

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

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

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

Mr. Anthony believes it is a mistake that many shops do not allow their engineers and machinists enough time to do what he calls research and development. “Owners and managers want to cut parts and ship them right now. Their philosophy insists that we don’t have time for R&D or that we will do it later,” he says. In rebuttal, he points to ADEX’s experiences with constant-chip-load machining and in-process gaging as examples of how important an in-house R&D program can be. “We give our engineers and machinists the time to experiment, dream and brainstorm in order to make the impossible become possible. Some of those things are helping us carve huge productivity gains out of our manufacturing operations,” he says.

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.

Eventually, Mr. Anthony and his team developed a calculator by which programmers can compute the best values for chip load and the other variables required for input when using the Dynamic Motion option. He considers this calculator a proprietary development for ADEX—a kind of trade secret—although he readily concedes that the recent releases of Mastercam have made it easier for other shops to plug in very workable Dynamic Motion values based on their own homework.

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

He singles out constant-chip-load machining as a prime example of R&D, because he is sure its benefits would not have been as substantial or pervasive without the R&D program to give it a boost. In the case of constant-chip-load machining, ADEX had to delve deeply into the performance characteristics of its preferred cutting tools as well as get acquainted with the kinematics of the multi-axis CNC machining centers and vertical turning lathe on its shop floor.

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

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.

“We call it constant-chip-load machining,” Charles Anthony says, referring to one of the CNC programming techniques that ADEX Machining LLC fully embraced after making it a focus of the shop’s in-house R&D program. Mr. Anthony, who is the director of engineering and operations at this 30-person shop in Greenville, South Carolina, has been promoting this concept of “job shop R&D” for several years, because he believes it gives ADEX a jump on new technology. He has seen this program (unusual for a small machining company) lead to a number of processes or capabilities that might not have been introduced there in time to get ahead of the curve on leading technology trends.

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

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

When a round, fluted cutter rotating at a certain speed contacts the workpiece, the sharp edges of the flutes form chips as the material is cut away. The size of these chips depends on how much of the cutter is in contact with the workpiece. The thickest chip formed is at 50-percent stepover—the radius of the cutter. When stepover is smaller than 50 percent, the chip formed will be thinner than what it would be at 50-percent stepover. As the degree of contact gets smaller and smaller, the resulting chips will be thinner and thinner in proportion. This effect is known as radial chip thinning.

Although ADEX had long been a user of Mastercam, the Dynamic Motion option had been neglected. Now the shop wanted to take a much closer look. Shortly thereafter, a few demonstrations on test workpieces created some distinct impressions. Dynamic Motion tool paths did not look like any tool paths the shop had used before. The cutting tool seemed to be swirling in and out of contact with the workpiece in moves that appeared to be inefficient and almost erratic.