New Tech Powers Productivity Gains in Indexable Milling - carbide insert cutters

 2024-06-16 11:58:40

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.

For anyone into machining, the video below is a must see. For those not in the know, tungsten carbide inserts are the replaceable bits that form the cutting edges of almost every tool used to shape metal. The video shows how powdered tungsten carbide is mixed with other materials and pressed into complex shapes by a metal injection molding process, similar to the one used to make gears that we described recently. The inserts are then sintered in a furnace to bind the metal particles together into a cohesive, strong part. After exhaustive quality inspections, the inserts are ground to their final shape before being shipped. It’s fascinating stuff.

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Mum: How are you liking it down the mine, Ken? Ken: Oh it’s not too bad, mum… we’re using some new tungsten carbide drills for the preliminary coal-face scouring operations. Mum: Oh that sounds nice, dear… Dad: Tungsten carbide drills! What the bloody hell’s tungsten carbide drills? Ken: It’s something they use in coal-mining, father. Dad: (mimicking) ‘It’s something they use in coal-mining, father’. You’re all bloody fancy talk since you left London.

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Yea, big diamonds are relatively useless compared to the absolutly essential bits of diamond found in these cutting inserts.

Most modern carbide inserts and solid carbide tools are coated with a thin film (between 3 and 20 microns, or 0.0001 to 0.0007 inch). The coating is typically composed of titanium nitride, aluminum oxide and titanium carbon nitride layers. This coating increases the hardness and creates a heat barrier between the cut and the substrate.

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The above explanation is correct in many cases. But since this is not an ISO/ANSI standard, some suppliers make their own adjustments to the system, and it is wise to be on the lookout for these changes.

The company’s Edge machine is capable of creating complex 3D cutting tool forms, including solid PCD-tipped end mills and drills under 1 mm.

In drilling, the center of the drill always has a cutting speed of zero, while the periphery has a cutting speed that depends on the drill diameter and spindle speed. Grades optimized for high cutting speeds will fail, and therefore should not be used. Most suppliers will offer just a handful of grades.

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

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.

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Shallow grooving is an exception to other types. As it shares similarities with turning, suppliers with a large selection of grooving inserts will usually offer a wider variety of grades for specific material groups and conditions.

You can do lots. You can use this tech to drill in mines or drill in concrete. Its cool that the tech goes back far enough that it was mentioned as a great thing back in the 1960’s/70’s when Monty Python was doing its show. Tungnsten carbide drilling and cutting is a wonderful thing. It makes many modern construction techniques possible, and makes this factory a real place of wonders. There’s plenty to do here. Need to ancher that gunsafe to the concrete floor. Tungsten carbide drill bits (along with a hammer drill) are there to make it work. Same goes if you want to run a wire through a concrete/brick wall or precut a crack in floor concrete so it doesn’t crack the wrong way. I was merely bringing up that that crazy band of mostly Brits back in the 60’s got it right in acknowledging the significance of this technology. :-)

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To navigate this maze, users must first understand what constitutes a carbide grade and how each element influences different aspects of machining.

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

While the metallurgic term “carbide grades” refers specifically to tungsten carbide (WC) sintered with cobalt, the same term has a broader meaning in machining: sintered tungsten carbide combined with coatings and other treatments. For example, two turning inserts made of the same carbide material but with a different coating or post-treatment are considered different grades. Carbide and coating combinations lack classification standardization, however, so different cutting tool suppliers use different names and classification methods for their grade charts. This can make grade comparison difficult for the end-user, an especially trying problem given that carbide grade suitability for a given application dramatically affects possible cutting conditions and tool life.

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

In parting or grooving applications, grade selection is limited due to cutting speed factors. That is, the diameter gets smaller as the cut approaches the center. The cutting speed thus decreases gradually. In parting-off to the center, the speed ultimately reaches zero at the end of the cut, and the operation becomes shearing instead of cutting.

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

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

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 right balance between hardness and toughness is the most crucial factor when selecting a grade for a particular application. Picking a grade that is too hard can lead to micro breakages along the cutting edge or even catastrophic failure. At the same time, a grade that is too tough will wear out fast or require decreasing the cutting speed, thus reducing productivity. Table 1 provides some basic guidelines for selecting the correct hardness:

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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.

Many cutter designs are available, and variable teeth spacing (or variable pitch) cutters can be used to influence milling stability. Let’s discuss why teeth spacing affects stability.

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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.

This is actually due to how these materials are made, which is slow and uses a HUGE amount of energy. They are crystals that are grown in laboratory environments by exposing a source material to very high temperatures for an extended duration. If we could harness the power of the sun more efficiently then these materials would be cheap.

Table 3 depicts a hypothetical chart of grades and their uses in different difficulties of turning applications, as might appear in a cutting tools supplier catalog. In this example, grade A would be recommended for a wide range of turning conditions, but not for heavy interrupted cuts, while grade D would be recommended for heavy interrupted turning and other highly unfavorable conditions. Tools such as the Grades Finder from MachiningDoctor.com can search for grades according to this designation system.

The substrate is the bare material of the cutting insert or solid tool underneath the coatings and post-treatments. It is typically made up of between 80- and 95-percent WC. To give the substrate the desired properties, material manufacturers add various alloying elements. The main alloying element is cobalt (Co) — higher levels of cobalt lead to greater toughness, while lower levels of cobalt lead to greater hardness. Very hard substrates can reach a hardness of 1800 HV and provide excellent wear resistance, but are very brittle and are only suitable for very stable conditions. Very tough substrates have a hardness of around 1300 HV. These substrates can machine only at lower cutting speeds and wear out faster, but have better resistance to interrupted cuts and unfavorable conditions.

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Again, there is no standard for these values, so they should be interpreted as a relative value within the specific grade table in which they appear. For example, a grade marked as P10-P20 in two catalogs of different suppliers could have a different hardness.

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

To choose the correct carbide grade for a particular application, look at the supplier's catalog or website for guidance. Although there is no formal international standard, most suppliers use charts that describe grades’ recommended working envelopes based on their "application range" as expressed in a three-character letter-number combination, such as P05-P20.

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

The following two numbers represent the grade's relative hardness level on a scale from 05 to 45 in increments of 5. A 05 application requires a very hard grade suitable for favorable and stable conditions. A 45 application requires a very tough grade suitable for unfavorable and unstable conditions.

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

Without an international standard for designating carbide grades or application ranges, users must rely on relative judgments and background knowledge for success.

Coincidentally, [John] at NYC CNC just released his own video from his recent jealousy-inducing tour of the Sandvik factory. That video is also well worth watching, especially if you even have a passing interest in automation. The degree to which the plant is automated is staggering – from autonomous forklifts to massive CNC work cells that require no operators, this looks like the very picture of the factory of the future. It rolls some of the Sandvik video in, but the behind-the-scenes stuff is great.

Despite only gaining traction about a decade ago, adding a post-treatment after coating has become an industry standard. These treatments are usually sandblasting or other polishing techniques that smoothen the top coating layer, reducing friction and, as a result, generated heat. Price differences are typically minor, and in most cases, it is recommended to favor grades with post-treatment.

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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.

Major suppliers usually provide separate series of grades for each material group. In each series, the grades range from tough for interrupted cuts to hard for continuous machining.

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

It seems a touch ironic that one of the main consumables in the machining industry is made out of one of the hardest, toughest substances there is. But such is the case for tungsten carbide inserts, the flecks of material that form the business end of most of the tools used to shape metal. And thanks to one of the biggest suppliers of inserts, Sweden’s Sandvik Coromant, we get this fascinating peek at how they’re manufactured.

The first letter represents the material group according to the ISO standard. A letter and a corresponding color are assigned to each material group.

Therefore, a grade for parting-off must be compatible with a wide range of cutting speeds, and the substrate should be tough enough to handle the shearing at the end of the operation.

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.

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

Unfortunately, price seems to scale exponentially with hardness. Tungsten carbide inserts run around $5-10 each. A good friend owns a machine shop and has a surfacing machine specifically for milling heads. Happily, it uses only one CBN insert, because the last one he ordered from China ran over $200. (He’s my friend for life now because I found a package of ten new American-made inserts from someone who must not have known their value—$45 including shipping.)

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Grades play a vital role in turning applications, more than in any other application. Because of that, when checking any supplier's catalog, the turning section will feature the largest selection of grades.

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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.

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“The degree to which the plant is automated is staggering – from autonomous forklifts to massive CNC work cells that require no operators, this looks like the very picture of the factory of the future.”

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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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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But if you need a REALLY hard material, the next best thing to diamond is cubic boron nitride (CBN). Knoop hardness is about half that of diamond, while tungsten carbide is about a fifth that of diamond. (Fun fact: hard as it is, diamond nonetheless can’t be used for precision machining iron/steel because it forms iron carbide; messes up the cutting edge.)

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

Just as there is no official standard for grade application ranges, there is no formal standard for grade designations. That said, most major carbide insert suppliers follow common guidelines in their grade designations. The "classic" designation follows a six-character format BBSSNN, where:

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

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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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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A grade marked as P10-P20 in the turning grades table could have different hardness than a grade marked as P10-P20 in the milling grades table, even in the same catalog. This difference comes down to the fact that favorable conditions vary across different applications. Turning applications are best tackled with very hard grades, but in milling, favorable conditions require some toughness because of its interrupted nature.

This extensive range of turning grades stems from the extensive range of turning applications. Everything from continuous machining, where the cutting edge is constantly engaged with the workpiece and suffers no impact but generates lots of heat, to interrupted cuts, which have heavy impacts, falls into this category.

Surface measurement is becoming increasingly important to ensure proper performance of a manufactured product. Advanced surface measurement tools are not only beneficial in the manufacturing industry but also have unconventional applications.

The wide range of turning grades also relates to the vast array of diameters in manufacturing, from 1/8 inch (3 mm) for Swiss-type machines to 100 inches for heavy industrial purposes. Because the cutting speed also depends on the diameter, there is a need for different grades that are optimized for either low or high cutting speeds.

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In milling, the range of grades on offer is smaller. Due to the application’s fundamentally interrupted nature, milling tools require tough grades with high impact resistance. For the same reason, the coating layer must be thin — otherwise, it will not withstand the impacts.

Dan, I try to read every single article you write on Hackaday. I can’t say that for all Hackaday authors. Keep up the great content! Sometimes I swear YouTube must be serving us the same video feeds when I see watched videos resurface!

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New Tech Powers Productivity Gains in Indexable Milling - carbide insert cutters

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