Are AMRs the next big trend in job shop automation? System 3R’s IMTS booth will emphasize both its specialty EDM tooling and its automation products, including an autonomous moving robot.

The 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.

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

According to Schmitz, Iscar’s HELI-GRIP tools are capable of external, internal and face groove/turn operations. The inserts have a double-ended, twisted body that avoids backside contact with the machined groove surface, and the tool’s geometry manages chip formation in both axial and radial directions.

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As an example, Schmitz described an application that involved machining a coupling from 3 "-dia., ¼ "-thick, 1010 steel tubing. The lathe operation consisted of cutting ID bores in each end of the coupling and machining a smaller bore in the center, then cutting the part off the tube. Chip control was a problem in the gummy steel, and push boring the inner bore packed chips into the tube, resulting in “tools blowing up left and right,” Schmitz said. To solve the problem, a grooving bar pull bored the back counterbore and simultaneously machined a 45º ID chamfer where the part was to be cut off. When ID machining was completed, the chamfer was the basis of a clean parting-off cut. Pull boring didn’t break the chip, but “we were able to manage the chips so that when we extracted the tool, the chips fell out of the workpiece and safely came to rest on the chip conveyor,” Schmitz said.

Condition of vibration involving the machine, workpiece and cutting tool. Once this condition arises, it is often self-sustaining until the problem is corrected. Chatter can be identified when lines or grooves appear at regular intervals in the workpiece. These lines or grooves are caused by the teeth of the cutter as they vibrate in and out of the workpiece and their spacing depends on the frequency of vibration.

Forget “additive versus subtractive.” Machining and metal additive manufacturing are interconnected, and enhance the possibilities for one another. Here is a look at just some of the ways additive and machining interrelate right now.

Multifunction grooving tools have been available for decades, and have seen extensive development over that time, according to Drape. As a result, much groove/turn tool improvement focuses on upgrading and modernizing existing technology.

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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.

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

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.

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.

Number derived from the net increase in the depth of impression as the load on the indenter is increased from a fixed minor load to a major load and then returned to the minor load. The Rockwell hardness number is always quoted with a scale symbol representing the indenter, load and dial used. Rockwell A scale is used in connection with carbide cutting tools. Rockwell B and C scales are used in connection with workpiece materials.

Custom tools are often required when standard tools cannot produce the desired groove form. As a result, THINBIT supplies both specials and standards with multifunction capability. Modifications to standards can include changes to tool details, including WOC and DOC, lead angle, top rake and chipbreaker configurations, and back and side clearances.

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.

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.

Form of milling that produces a flat surface generally at right angles to the rotating axis of a cutter having teeth or inserts both on its periphery and on its end face.

Dimension that defines the exterior diameter of a cylindrical or round part. See ID, inner diameter.

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

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

While grooving/turning tools are typically designed to maximize productivity in certain materials, some can be more broadly applied. For example, Kennametal’s Grooving Universal Positive (GUP) geometry lowers cutting forces and enhances chip control when cutting stainless steels and high-temperature alloys, and the tools are suitable for other applications as well, according to the company.

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.

About the Author: Bill Kennedy, based in Latrobe, Pa., is a contributing editor for Cutting Tool Engineering. He has an extensive background as a technical writer. Contact him at (724) 537-6182 or by e-mail at billk@jwr.com.

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.

Despite the process improvement advantages of multifunctional grooving systems, many shops remain unaware of the tools’ full capabilities. “We continuously hear at trade shows, ‘Oh heck, I had to make a tool to do that myself. I wish I would have known about this,’ ” said HORN’s Drape. CTE

CNC machine tool capable of drilling, reaming, tapping, milling and boring. Normally comes with an automatic toolchanger. See automatic toolchanger.

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."

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

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 applying a grooving insert in a turning operation, a controlled degree of deflection is desirable. Without deflection, the tool edge sits flat on the part and the extended surface contact causes chatter. Conversely, when side-cutting pressures deflect the tool in a groove/turn operation, the insert tilts slightly, reducing edge contact with the workpiece. Precise control of variables can achieve tolerances as tight as ±0.0004 ".

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

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

The L.S. Starrett Co. has been manufacturing precision measurement tools in Athol, Massachusetts, since 1880. Attention to U.S. manufacturing often focuses on reshoring manufacturing from other countries, but Starrett never left. The facility in Athol employs hundreds and produces thousands of tools that remain vital for measurement in machining and other fields.

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

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

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

In addition to ongoing insert geometry development, new tool bodies can improve groove/turn performance. For example, Kennametal introduced bodies with a shorter tool overhang distance (CD) than standard ones. Reducing the extension of the insert beyond the body in these short-overhang, A-4 holders increases tool rigidity and allows higher feed rates and faster turning than tools with longer overhang, according to Kennametal.

King said multifunction grooving tools can also simplify the formation of groove geometry, enable features of the geometry to be linked on a single tool and increase productivity. “The applications are only limited by the design of the tool or the limitations of the structural strength of the tool,” he said.

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

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.

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

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

Essentially a cantilever beam that holds one or more cutting tools in position during a boring operation. Can be held stationary and moved axially while the workpiece revolves around it, or revolved and moved axially while the workpiece is held stationary, or a combination of these actions. Installed on milling, drilling and boring machines, as well as lathes and machining centers.

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

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

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

A turning operation in which a groove is produced on the periphery or inside a hole of a workpiece. The grooving tool moves at right angles to the axis of rotation.

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

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

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

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

Sandvik Coromant’s GC1205 and GC1210 physical vapor deposition (PVD) insert grades enable secure, high-precision turning of aged, nickel-based, heat-resistant superalloys (HRSA).

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

The Walter Turn toolholder features rake-face cooling to help break and control chips, and double flank-face cooling directly at the cutting edge to extend tool life.

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.

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

Many grooving tools are designed for certain work materials, but can still be used in other applications. Etling cited the example of tools with Kennametal’s Grooving Universal Positive (GUP) geometry, which produces low cutting forces and good chip control in stainless steels and high-temperature alloys, according to the company. Although those materials were the initial design targets for the GUP tools, he said the geometry has found wider applications in other materials and even selected cutoff operations.

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

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.

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.

A tool operating in a deflected orientation will not produce a square shoulder, he added. “The key is to program the tool to leave the cut at a 45º angle before reaching the side of the shoulder, and then plunge the shoulder separately,” Schmitz said. “When you are plunging, you don’t have deflection.” Similarly, if a groove needs to be machined at the end of a turned section of the part, the tool should be moved in the direction opposite the feed for about 0.1mm, releasing the deflection, before the plunge grooving begins.

In addition to creating specific part features, tools that perform more than one function can improve shop processes, including reduced cycle times due to fewer tool changes, increased open turret locations, simplified tool ordering and reduced tool inventory because the same tools can be used on multiple jobs. Because one tool can be programmed to create a variety of features, a change in part geometry can often be accomplished by simply changing a CNC program rather than mounting a new tool.

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.

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

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

Stainless steels possess high strength, heat resistance, excellent workability and erosion resistance. Four general classes have been developed to cover a range of mechanical and physical properties for particular applications. The four classes are: the austenitic types of the chromium-nickel-manganese 200 series and the chromium-nickel 300 series; the martensitic types of the chromium, hardenable 400 series; the chromium, nonhardenable 400-series ferritic types; and the precipitation-hardening type of chromium-nickel alloys with additional elements that are hardenable by solution treating and aging.

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

The tools’ capabilities can help shops respond to ongoing manufacturing trends. “Long-running jobs are no longer the norm, and ‘get in and get done’ is the mentality,” King said. When a short production run ends, multifunction tools are “more versatile and can be repurposed for the next job,” he said. The tools’ adaptability also facilitates quicker turnaround when a shop’s customer needs an emergency delivery.

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.

Drape pointed out that a thread and a groove differ really only in name. “A thread is simply a helical, continuous groove.”

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.

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

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.

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

Matt Schmitz of Iscar Metals said the basic design of a grooving insert and holder can facilitate chip management in some situations. For example, chip control can be challenging when boring a blind-hole, especially with smaller diameters where the boring bar and ISO insert occupy much of the space in the bore.

One grooving tool can be programmed to create a variety of features. That means part geometry can be altered by simply changing a CNC program rather than mounting a new tool.

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.

Hole or cavity cut in a solid shape that does not connect with other holes or exit through the workpiece.

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

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

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!

Enlarging a hole that already has been drilled or cored. Generally, it is an operation of truing the previously drilled hole with a single-point, lathe-type tool. Boring is essentially internal turning, in that usually a single-point cutting tool forms the internal shape. Some tools are available with two cutting edges to balance cutting forces.

Duane Drape, national sales manager for HORN USA Inc., Franklin, Tenn., provided a nontraditional take on grooving: “Paraphrasing our owner, Lothar Horn, we define grooving as machining between two flanks or two shoulders—and one flank or shoulder doesn’t necessarily have to be there.”

Employing the tool in a pull-boring mode can further enhance chip evacuation, Schmitz said. In pull boring, the tool travels into the bore without cutting, is engaged at the bottom of the bore, and then is retracted or pulled towards the hole mouth. Chips are formed on the backside of the insert and coolant can evacuate the chips.

Most shops associate “grooving” only with cutting a simple slot around the OD of a shaft. However, some grooving tools have capabilities beyond that, including turning, contouring and facing. According to toolmakers, keys to maximizing benefits from multifunction grooving tools are understanding their capabilities and having confidence in their application.

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

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.

Step that prepares a slug, blank or other workpiece for machining or other processing by separating it from the original stock. Performed on lathes, chucking machines, automatic screw machines and other turning machines. Also performed on milling machines, machining centers with slitting saws and sawing machines with cold (circular) saws, hacksaws, bandsaws or abrasive cutoff saws. See saw, sawing machine; turning.

When turning with turn/groove tools, users can typically double the feed rate compared to grooving, according to Etling. “For example, if you are grooving at 0.005 ipr, you can turn at 0.010 ipr,” he said. “That would be equivalent to some of the ISO turning inserts available.” He cautioned that the relationship only represents a rule of thumb. “You’d have to look at the whole setup, including the workpiece and tool overhang. Typically, you go to a higher feed rate if you are looking for higher metal-removal rates, and apply a slower feed rate for a finishing pass.”

Cone-shaped pins that support a workpiece by one or two ends during machining. The centers fit into holes drilled in the workpiece ends. Centers that turn with the workpiece are called “live” centers; those that do not are called “dead” centers.

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Not all grooving inserts can deflect, Schmitz noted. For example, inserts in Iscar’s PENTA tooling line have a rigid, deflection-resistant mount to provide maximum stability when shallow grooving, parting and recessing. However, the tools can perform light side turning because a concave shape on the front cutting edge reduces the amount of contact between the insert and the workpiece.

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

Process of both external (e.g., thread milling) and internal (e.g., tapping, thread milling) cutting, turning and rolling of threads into particular material. Standardized specifications are available to determine the desired results of the threading process. Numerous thread-series designations are written for specific applications. Threading often is performed on a lathe. Specifications such as thread height are critical in determining the strength of the threads. The material used is taken into consideration in determining the expected results of any particular application for that threaded piece. In external threading, a calculated depth is required as well as a particular angle to the cut. To perform internal threading, the exact diameter to bore the hole is critical before threading. The threads are distinguished from one another by the amount of tolerance and/or allowance that is specified. See turning.

In the latest episode of our View From My Shop series, MMS Editor-in-Chief Brent Donaldson visited the JN Shapiro Watches headquarters and production facility where Founder Joshua Shapiro—a history teacher turned watchmaker—realized his dream of "making a watch from scratch and everything in it."

Lee Wimmer invited us to tour his second-generation family-owned machine shop in Perkasie, PA. This video explores the production processes behind precision-machined parts for both Wimmer Custom Cycle and LS Wimmer Machine Co., and shows how ingenuity and determination are still at the heart of American manufacturing. Today, both companies are now managed by Wimmer’s three sons.

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.

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

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

The GC1205 and GC1210 insert grades are designed to make surface requirements for aerospace engine components easier to achieve. Together, they are said to cover a large application area during last-stage machining (LSM) and intermediate-stage machining (ISM).

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.

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

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.

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.

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

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.

A flat-bottom hole requiring a groove at the bottom is a good example, he said. “If it couldn’t cut all the way down to the face at the bottom, it wouldn’t be able to cut the groove,” Drape said.

Angle between the side-cutting edge and the projected side of the tool shank or holder, which leads the cutting tool into the workpiece.

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.

“The combination of features multifunction [grooving] tools can create is their greatest asset,” said Ken King, COO of THINBIT/Kaiser Tool Co. Inc., Fort Wayne, Ind. “Those features include arcs, angles, chamfers, radii, grooves, face grooves and any other feature you can machine on a lathe.”

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.

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

Typical components the grades can machine include gas turbine discs, casings, blisks, spools, shafts and blades. These grades are also well suited for demanding applications such as power generation turbines and medical implants made of cobalt chrome. GC1205 is a finishing grade for machined surfaces in LSM and ISM applications. GC1210 is designed to perform in applications where more toughness is required, and is mainly used in ISM applications for nonmachined surfaces.

Space provided behind a tool’s land or relief to prevent rubbing and subsequent premature deterioration of the tool. See land; relief.

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

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.

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

Conversely, when side-cutting pressures deflect the tool in a groove/turn operation, the insert tilts slightly and tool edge contact with the workpiece is reduced. Schmitz said the deflection must be carefully controlled by managing several variables, including feed rate, cutting speed, DOC, tool overhang, insert width support and the workpiece’s cutting characteristics. When those factors are balanced and kept constant, tolerances as tight as ±0.0004 " can be achieved. Schmitz said the results are similar to that of wiper-geometry turning inserts for imparting fine surface finishes.

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

Pairing automation with air-driven motors that push cutting tool speeds up to 65,000 RPM with no duty cycle can dramatically improve throughput and improve finishing.

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

“But in a side-turning operation with a properly designed groove/turn insert, if you are taking a deep enough DOC, the chip wants to curl back toward the insert and the part and typically will break easily,” he said. “Programming can optimize each of the three cutting edges, but the programmer must ensure that only one cutting edge is engaged in the cut at a time, and be aware that, when generating radii during a plunging move, that the side edge may engage any material that has not been cleared away.”

“We are not reinventing the wheel,” he said. “For example, we continuously improve chipbreaker designs.” He pointed out that a tool cutting grooves in castings or forgings, especially on a lathe, does not cut with the full face of the insert because a casting has draft angles. Cutting with only portions of the face can complicate chip control. In response, tool manufacturers have developed chipbreaker geometries such as those on HORN’s HR (hard roughing) inserts. The design features a platform chipformer for long-chipping materials, such as low-carbon steel.

Yet despite the added geometry, many shops presume that moving a grooving insert in the Z-axis to turn or profile will magnify chip control problems. “You would think that would be one of your biggest challenges, but it’s not,” Schmitz said. “It can be difficult to break a chip in a simple plunge-grooving cut, especially in a gummy material.

There are several key features that can help in working with the high-level performance of HRSA materials. A hard, fine-grained substrate, PVD coating technology and optimized edge-line integrity provide increased flank wear and secondary notch wear resistance, improved edge-line security and reduced flaking.

Saunders adds, “The release of these two new grades offers the opportunity to increase cutting data while also prolonging tool life predominantly in last-stage machining and intermediate-stage machining of aerospace and medical components.”

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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.

Schmitz said some shops are skeptical about side turning with a grooving tool because “they look at a grooving tool, get nervous and say, ‘I’m not supposed to turn with this thing!’ ” Some of the concern regards tool deflection caused by side forces that are not present in simple plunge grooving. Actually, a controlled degree of deflection is desirable. “When it comes to groove/turning, if you don’t get deflection, the tool edge sits flat on the part and is going to chatter to beat the band because there is a lot of surface contact,” he said.

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.

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

Toolmakers need to educate end users on the enhanced capabilities of groove/turn tools, according to Scott Etling, manager, global threading, grooving and cutoff for Kennametal Inc., Latrobe, Pa. What often complicates the tool choice, however, is that grooving platforms are typically proprietary.

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.

Endless band, normally with serrated teeth, that serves as the cutting tool for cutoff or contour band machines.

Machining grooves and shallow channels. Example: grooving ball-bearing raceways. Typically performed by tools that are capable of light cuts at high feed rates. Imparts high-quality finish.

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

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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.

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

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

Some users may need to overcome preconceptions about multifunction grooving tools, according to Matt Schmitz, turning product manager, U.S. north central, Iscar Metals Inc., Arlington, Texas. While a traditional grooving tool usually has a dead-sharp front edge, a grooving/turning insert includes a chipformer and edge preparations on the front, left and right sides of the insert to enhance tool life, productivity and chip control, he said. Edge preparations include T-lands for machining cast iron, ground periphery and diamond polish for aluminum and more positive geometries for high-temperature work materials.

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When revising part designs, investigate the 3D CAD, the 2D drawing and the part’s functional requirements to determine which details should be tightened up.

The GC1205 and GC1210 PVD insert grades are designed to make surface requirements for aerospace engine components easier to achieve.

The same tool used for grooving the bottom of a hole can also bore/mill the hole. “When that is done on a machining center, the tool has to rotate and helically interpolate, using the same process as a thread mill,” he said. “Although it is opening the bore, it is still a grooving tool.” If the bore and the top face of that component have to be perpendicular to each other, the machinist can facemill with the same insert.

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).

Multifunction grooving systems include tools engineered for application on machining centers as well as lathes. An example is the new line of M275 cutters from HORN USA. The cutters can accept grooving inserts as well as facemilling inserts and have multiple teeth to maximize metal-removal rates.

Although programming rough grooving/turning operations is typically straightforward, peak accuracy, especially in finishing, usually requires in-process adjustment, according to Schmitz. “For finish cuts, it’s not going to be ‘program it, hit the green button and go,’ ” he said. “You have to tweak it.” He said changing the feed rate is typically the best starting point for adjustments.

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

Drape’s definition of multifunction grooving tools includes those used on machining centers as well as lathes. An example from HORN is the line of M275 cutters it will introduce at IMTS. The cutters can accept grooving inserts from 1.2mm to 3.25mm wide, but can also handle facemilling inserts capable of 4.0mm DOCs. The standard cutters range in size from 31mm in diameter with four inserts to 98mm in diameter and 10 inserts. Drape said the tools are not for the general facemilling market, but for applications where a smaller tool with multiple teeth is needed to achieve high productivity.

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

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.

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

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?

“The chip wants to go in front of the tool and back around the bottom of the bore,” Schmitz said. On the other hand, a grooving insert, by design, generally extends farther from the centerline of the bar than an ISO boring insert (offering greater Tmax, or distance between the cutting edge and toolholder) and the greater clearance between the insert tip and the holder provides ample room for chip flow.

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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

The main purpose of groove/turn tools is to create a variety of part features with one tool. However, the tools’ configuration may also allow them to solve problems other tools can’t.

When used in lathe or screw-machine operations, this process separates a completed part from chuck-held or collet-fed stock by means of a very narrow, flat-end cutting, or parting, tool.

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

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.

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

“For our customers, this translates into possibilities to run the inserts at higher cutting speeds with GC1205 and increased tool life with GC1210. Additionally, it ensures consistent and predictable tool life while reaching the required surface integrity demands for critical aerospace components,” says Martin Saunders, global product application specialist for turning.

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