MACH 2024: Horn unveils five new tooling solutions - carbide insert geometry

 2024-06-19 15:14:35

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.

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.

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

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.

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

Scot Forge’s Brandon James indexes a Hex-Turn insert, which will last reliably through the entire machining process on the big Inconel forging. The shop’s previous, square inserts typically failed after just one inch of feed.

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.

When inserts rupture in Inconel, the typical reaction is to “take the load off” the insert by lightening the cut, says Jim Whitley of cutting tool manufacturer Ingersoll (Rockford, Illinois). However, this reaction may be ill-advised. Shops tend to forget that rupture often begins with an edge going dull, which, in turn, overloads the insert to the point of breaking down. “This can happen within a few seconds, so it’s easy to miss wear as the root cause,” he explains. “Assuming that adequate machine horsepower is available, the better answer is to go to a stronger insert with a gentle lead angle and make fewer, deeper passes.”

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

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

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.

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.

Cutting deeper reduces the number of required passes, which, in turn, reduces the insert’s exposure to the hot, abrasive environment at the cutting edge. However, as Mr. Whitley explains, an insert’s ability to withstand a deeper cut depends on its strength. That’s why—true to its name—the Hex-Turn features a hexagonal geometry, a shape that is second only to round inserts in strength, he says.

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.

Scot Forge is a diversified, employee-owned forging company that has been in business for more than 100 years. It has plants in Clinton, Wisconsin as well as Franklin Park and Spring Grove, Illinois. By customer preference, most of the company’s output is delivered in the forged and rough-machined condition. Howard Dempsey is supervisor of the machine and saw shop at the Clinton plant, a site that runs 24 hours a day, five days a week and houses 200 employees, 50 of whom are machinists. He says the part that prompted the company’s switch to Hex-Turn is just one of a growing number of jobs involving high-temperature alloys, which management has identified as a trend. “We get about six reorders a year for that part, and orders for other Inconel and titanium forgings are rising,” he notes. “So, we decided it was time to develop a best practice for machining them.”

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.

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

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.

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.

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

Ingersoll product manager Raymon Avery adds that the other difference-maker is the 45-degree lead angle, which is made intrinsically possible by the insert’s hex shape and chipbreaker top face. This lead angle provides a gentler entry into the work that reduces cutting forces and protects the insert. Meanwhile, the contoured top face breaks up the long, hot, gummy chips characteristic of Inconel alloys and deflects them away from the insert to reduce heat.

The TCS18 and TCL18 inserts are designed for left-hand cuts, expanding product lines that previously offered only right-hand inserts.

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.

Following Mr. Whitley’s advice paid dividends at Scot Forge, which saved $2,400 per part on one tough Inconel turning application after retooling to Ingersoll’s Hex-Turn inserts and adjusting machining parameters accordingly. Based on its success with that job, the company has standardized on Hex-Turn and those same parameters for rough turning a growing variety of Inconel parts.

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.

By changing to a hex-shaped turning insert with a 45-degree lead angle, this shop saved thousands of dollars on a difficult Inconel turning application.

The Megacoat Tough coating combines a wear-resistant layer on the surface adhered to high-content CBN, which provides greater fracture resistance when encountering interruptions.

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.

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

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

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.

Previously, machining took 105 hours and 40 passes at a feed rate of 0.02 ipr, a cutting depth of 0.075 inch and a speed of 38 sfm. The turning and facing operations required different inserts, and the job typically ate through 69 inserts per part. In fact, tool failure was so prevalent that inserts required indexing every half inch, and the job had to be run 100-percent attended. Moreover, the main failure mode was edge rupture, which renders the insert useless even if some edges go unused. All the while, the operation tied up a large vertical lathe from MAG Giddings & Lewis (Fond du Lac, Wisconsin) that the company needed for other work.

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.

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

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

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.

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?

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

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.

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

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

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

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.

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."

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.

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

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

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

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

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.

Thanks to a 45-degree lead angle and top-face chipbreaker, the Hex-Turn inserts outlast their predecessors by 69 to 1 while reducing cycle time on the Inconel forging by 15 hours.

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

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.

Tool-holder-spindle-machine combinations each have a unique dynamic response in the same way that each person has a unique fingerprint, which can be revealed using modal testing.

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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

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.

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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 large Inconel hub requires rough turning and facing to remove about 0.8 inch of material across its entire diameter. As forged, it measures 98 inches in diameter, with a step-down to a 93-inch diameter on one end.

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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.

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

In all, the drop-in retooling saved $1,500 in cycle time and $900 in tooling costs—per part. Cost savings aside, having a secure process for such difficult material enables Scot Forge to bid more confidently on Inconel jobs and to compete more effectively in a high-tech niche. “This improvement enables us to maintain competitive costs for machining Inconel,” Mr. Dempsey says. “Otherwise, we would have been forced to raise prices to cover the excessive cost of tooling and the resulting sub-par productivity.”

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

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

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

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

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

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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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Get sensible, real-world automation solutions during this half-day workshop co-located with IMTS 2024.

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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

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.

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

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

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

With an eye toward a better standard practice for turning this class of alloy, Mr. Dempsey asked all his tooling vendors for their best ideas and began testing different solutions. Most tools the company tested produced minor improvements at best. The exception was the Hex-Turn, which features a 45-degree lead angle presentation and top-face chipbreakers. Tests showed these inserts could significantly improve cycle time and tool life compared to the square, flat-topped, zero-lead models the shop had been using.

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.

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.

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

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.

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.

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.

That was the case with Scot Forge’s problem component, a huge Inconel No 7718 hub used in nuclear turbomachinery. This part requires rough turning and facing to remove about 0.8 inch of material across its entire diameter, primarily for truing up. As forged, it measures 98 inches in diameter, with a step-down to a 93-inch diameter on one end.

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 company standardized parameters for the new tool at an 0.015-ipr feed rate (slightly less than the previous rate), an 0.15-inch cutting depth (double the previous setting) and a speed of 60 sfm (60 percent higher than the previous setting). Despite more than doubling the cutting rate, each insert lasted through the whole part. Cycle time dropped 15 percent. “We would have been happy with just the tool life improvement,” Mr. Dempsey says. “The throughput gain was an unexpected bonus.”

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.

Ingersoll’s Raymon Avery and Scot Forge’s Howard Dempsey stand amid finished Inconel hubs while discussing how to tackle the next tooling issue. Mr. Avery or his colleague Jim Whitley meet regularly with Scot Forge representatives to stay ahead of the curve in production planning.

While taking on Inconel, titanium and other high-temperature alloys can provide a competitive advantage and a source of pride, these exotic materials are abrasive to tools and impose high cutting forces. Additionally, they tend to generate hot, stringy chips that can stick to the cutting edge and overheat the tool. As a result, such work can create bottlenecks, tie up machines and increase tooling costs.

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

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

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

MACH 2024: Horn unveils five new tooling solutions - carbide insert geometry

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