Despite a feeling of general turbulence in the industry, some companies are performing incredibly well. Take Ceratizit UK & Ireland for example which is on track to have its best ever year. Not only that, but the tooling specialist also ended 2023 on a real high with an insanely busy open house in December which saw 150 visitors pass through its doors – one of which was Dave Tudor. You can always have too much of a good thing so Ceratizit doesn’t tend to host open houses often. In fact, the December 2023 event was only the second open house held at the company’s Technical Centre located on the Advanced Manufacturing Park in Sheffield. The first, which took place in October 2021, also marked the official opening of the facility. The common denominators for both events were extremely high visitor interest, loads of product demos and plenty of technology on offer. Going for gold Like, for example, Ceratizit’s new range of ISO-P multi-edged indexable carbide turning inserts with wear detection which were put through their paces on a Mazak Integrex i-250H multitasking machine in the Tech Centre during the open house – a machine that combines turning with 5-axis milling. The demonstration showcased various products from the range: CNMG for end facing and roughing the O/D; RCMT button inserts for the trochoidal turning of a recess; and DNMG for finish turning.Ceratizit’s ISO-P inserts comprise a wear-resistant grade with a high degree of elevated temperature resistance for machining steel at high cutting speeds. Different grades are available for individual cutting conditions including roughing, medium machining and finishing and all have a Dragonskin coating to reduce friction and prevent and identify wear. An interesting aspect of these ISO-P (the ‘P’ denotes performance) inserts is a gold-coloured outer indicator layer so operators can physically see how the tool is wearing in real-time. This forms part of a triple layer arrangement comprising: a Ti (C, N) highly textured base layer; an Al2O3 multilayer; and the gold-coloured TiN outer layer. “Cutting ISO-P steels can be challenging but due to improved layer performance the new inserts represent up to 45% longer tool life compared to our older grades depending on cutting speed,” explains Ceratizit UK & Ireland’s technical manager Shaun Thornton. “Our customers appreciate the gold indicator layer because it clearly shows when the edge is wearing and needs to be changed. The main benefit is that cutting edge life can be optimised. With the older black inserts, wear was much more difficult to detect. The gold layer offers no performance enhancements per se; it’s purely a visual indicator.” Know the drill Solid carbide drills can be frighteningly expensive – especially in larger diameters – so readers will no doubt be keen to learn that Ceratizit’s new WPC change drill offers all the performance of a solid carbide drill in terms of cutting data, but it features an interchangeable indexable insert tip. This means you only have to change the insert rather than the entire drill which is far more cost-effective. “This product is manufactured by Komet which is part of the Ceratizit Group,” Mr Thornton explains. “Unlike a solid carbide drill, the body holder is steel which offers a degree of flex when machining – and you get full twist drill geometry. WPC holders and inserts are available in a wide range of diameters from 14mm to 30mm and in lengths of 3 and 5xD,” he adds. For deep hole drilling applications, Ceratizit’s WTX high performance deep hole drills can now drill to depths of 50xD with an appropriate pilot hole. With diameters spanning 2mm to 12mm, the design ensures excellent chip evacuation and alignment precision. The Nakamura SC-200IIL has an exceptionally large machining area for a small footprint machine Closed loop quality assurance Machine. Measure. Correct: the Komflex measurement system is a joint collaboration between Ceratizit and measurement and testing technology specialist Blum-Novotest. The system was demonstrated at the open house on an XYZ UMC-5X 5-axis machine. This is an all-encompassing closed loop boring system that combines production with quality assurance. It comprises a Ceratizit fine boring head which communicates with the Blum’s measuring stylus wirelessly through its RC66 interface, effectively enabling automatic, in-process diameter correction on holemaking and boring processes (6-120mm diameter range). The spindle head and Blum system are initially paired like any other wireless devices. Aside from the obvious advantages of reducing production times and avoiding scrapping eye wateringly expensive parts, the cost saving implications are significant – and this, plus live machining data is visible via a user-friendly, downloadable Amortisation app accessible through the machine tool’s CNC. It really is a case of machine, measure, correct. And because Komflex is a highly secure, closed loop system, it can run unattended, requiring little or no manual intervention. There’s virtually no chance of human error and it can even reinitialise the tool or instigate a change after predetermined wear limits are reached. Literally set the parameters and go. Tool management: the best of both worlds Like practically all tooling companies, Ceratizit offers its own tooling cabinet management system called ToolSupply Tool-O-Mat. This is a closed system and is totally managed, restocked and audited by Ceratizit on behalf of its customers. Now however, Ceratizit has introduced a brand new, hot off the press open tool management system called MyTOM. Shaun Thornton explains. “The advantage with open systems is that the customer, not Ceratizit, manages the stock on equipment they’ve already bought,” he states. “MyTOM needs our Tool-O-Mat 840 closed system to work but it means that items like partially used tools, gauges, measuring equipment, PPE, tool regrinds and cutter bodies can be booked back into the system rather than finding themselves ‘lost’ in operator toolboxes or worse still, thrown away. “You can partially use a tool for example and then return it back to stock so it becomes controlled again.” MyTOM is essentially a separate cabinet that’s linked to a Tool-O-Mat 840 system (it can’t operate standalone) so customers can get the benefits of owning both a closed and open tool management system. Ceratizit takes care of the Tool-O-Mat cabinets; the customer manages MyTOM. The latter has its own browser-based operating software that can be accessed via a desktop computer, laptop or mobile device so taking items out of stock and booking them back in (if applicable) is an absolute breeze. Tech Centre evolution Since its inauguration in 2021, the Technical Centre has been a phenomenal success for both Ceratizit and partner XYZ Machine Tools. It’s used mainly for customer projects, speccing out the right tools for the job in hand. “It’s all about working closely with our customers and making their lives easier,” Mr Thornton affirms. “Sometimes they’ll simply send in a drawing and we’ll work from that; or other times the customer will come here and we’ll work through things together. “Since we opened the centre, it’s been very busy. Both ourselves and XYZ use the facility extensively and there are always a large number of projects running at any one time. We also use it as a training facility for our staff on new product introductions, our apprentices and even customers. The skills shortage has affected everyone, and we often find our clients need an extra helping hand. For us it’s all part of the service.” At the moment, Ceratizit occupies two sites in Sheffield approximately two miles apart – but not for much longer because the plan is to move both operations to a single site in 2026. Work is already underway in locating a suitable location. Laying the foundations for continued success I mentioned at the top of this article that Ceratizit UK & Ireland is on track for a record year. The company’s financial year runs from 1st March to 28/29th Feb and for 2023/24 turnover is set to top a staggering £45 million. Remember this is a tooling company – not a capital equipment manufacturer that can sell a machine tool for £1m+. Quite an achievement. “I am delighted to report that Ceratizit UK & Ireland will reach a turnover level of £45m+ this year which represents year on year growth in excess of 15%+,” enthuses Tony Pennington, Ceratizit’s managing director, cutting tools North Europe. “I believe this is down to several factors: the strong customer relationships built by our long established, 42 strong team of engineers who are supporting clients on a daily basis to provide solutions that save them time and money. “In addition, the further investment we have made in our UK stock to hold over 8,500 lines of our fast-running tools providing a guaranteed next day before noon delivery has given another advantage to our customers. Furthermore, our free of charge vending solutions, providing 24/7 access to tools with full control helps keep our customers’ spindles turning. “We work extremely hard to provide what we believe to be the best customer service in the industry,” he concludes. “We’ll continue to invest in people and technology to drive the company forward year on year.” Ceratizit UK & Irelandwww.ceratizit.com

MSC Industrial Supply Co. UK (MSC) is celebrating a successful season after sponsoring two local youth football teams during the 2023/2024 campaign.

“You can partially use a tool for example and then return it back to stock so it becomes controlled again.”

After indexing the tool, an offset is not always required because the repeatability of these tools is very accurate. Setups are easier with this type of tool as well, because the location of the tool is predictable.

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“Cutting ISO-P steels can be challenging but due to improved layer performance the new inserts represent up to 45% longer tool life compared to our older grades depending on cutting speed,” explains Ceratizit UK & Ireland’s technical manager Shaun Thornton.

“Our customers appreciate the gold indicator layer because it clearly shows when the edge is wearing and needs to be changed. The main benefit is that cutting edge life can be optimised. With the older black inserts, wear was much more difficult to detect. The gold layer offers no performance enhancements per se; it’s purely a visual indicator.”

According to Pat Nehls, product manager for Walter USA, solid tools produce more precise features, which makes them the preferred tool when finishes matter.

And, in an effort to control production costs, many tooling manufacturers now offer carbide recycling programs to reduce their dependence on new carbide purchases.

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The HyproJET X6 from Ceratizit is based on an improved and patented design which makes is possible to increase cutting performance, leading and lifetime.

“Solid-carbide end mills perform at their best when held in a shrink-fit holder, but removing a used solid-carbide tool from a shrink-fit adapter can be cumbersome and time-consuming,” said Mitchell. “An indexable end mill is simple to index; in fact, most indexes can be performed right on the machine in seconds.”

“Reconditioned solid drills and mills must be reset after reconditioning due to the changed overall length and diameter,” said Nehls.

Indexable tools, on the other hand, have greater diameter tolerances due to the tolerance of the basic body as well as the tolerance of the insert used. For this reason, indexable drills are normally considered roughing tools.

Solid carbide drills can be frighteningly expensive – especially in larger diameters – so readers will no doubt be keen to learn that Ceratizit’s new WPC change drill offers all the performance of a solid carbide drill in terms of cutting data, but it features an interchangeable indexable insert tip. This means you only have to change the insert rather than the entire drill which is far more cost-effective.

During production, indexable tools typically run at lower inches per minute (longer cycle time) than solid-carbide tools because they use a lower feed per revolution. However, the cost per feature will normally be lower because inserts have two or more usable cutting edge

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And because Komflex is a highly secure, closed loop system, it can run unattended, requiring little or no manual intervention. There’s virtually no chance of human error and it can even reinitialise the tool or instigate a change after predetermined wear limits are reached. Literally set the parameters and go.

On the other hand, Nehls said that indexable drills have a tighter diameter tolerance band because of their assembled nature. Cycle time may be increased, but the cost per hole is generally lower. Ultimately, the requirements of each project guide tool choice.

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“The advantage with open systems is that the customer, not Ceratizit, manages the stock on equipment they’ve already bought,” he states. “MyTOM needs our Tool-O-Mat 840 closed system to work but it means that items like partially used tools, gauges, measuring equipment, PPE, tool regrinds and cutter bodies can be booked back into the system rather than finding themselves ‘lost’ in operator toolboxes or worse still, thrown away.

The HyproJET X6 from Ceratizit is based on an improved and patented design which makes is possible to increase cutting performance, leading and lifetime.

Initial setup time is increased with indexable tools because the inserts must be loaded into the tool body. Subsequent tool changes can be more economical in terms of time, though, because resetting the tool length is not necessary when indexing the inserts.

Aside from the obvious advantages of reducing production times and avoiding scrapping eye wateringly expensive parts, the cost saving implications are significant – and this, plus live machining data is visible via a user-friendly, downloadable Amortisation app accessible through the machine tool’s CNC. It really is a case of machine, measure, correct.

According to the show organiser, the recent UK Metals Expo, which took place at the NEC in Birmingham in September concluded with resounding success, exceeding expectations for all involved.

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The demonstration showcased various products from the range: CNMG for end facing and roughing the O/D; RCMT button inserts for the trochoidal turning of a recess; and DNMG for finish turning.Ceratizit’s ISO-P inserts comprise a wear-resistant grade with a high degree of elevated temperature resistance for machining steel at high cutting speeds. Different grades are available for individual cutting conditions including roughing, medium machining and finishing and all have a Dragonskin coating to reduce friction and prevent and identify wear.

Some operations may require solid tools when the hole diameter is less than the size range of indexable tools.

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“I believe this is down to several factors: the strong customer relationships built by our long established, 42 strong team of engineers who are supporting clients on a daily basis to provide solutions that save them time and money.

The latter has its own browser-based operating software that can be accessed via a desktop computer, laptop or mobile device so taking items out of stock and booking them back in (if applicable) is an absolute breeze.

According to Walter USA Product Manager Pat Nehls, productivity, not price, should drive purchasing decisions. New coatings and high-performance tool designs are two examples of productivity-boosting technologies that can have a dramatic effect on performance.

New technology has enabled some cutting tool manufacturers to produce indexable end mills, which essentially are small end mills threaded into a shank.

First, the end mill needs to be removed, reground, and placed back into the collet holder. Then the tool must be set up using a height gauge or tool presetter, before being placed back in the machine. Following this, a trial cut is typically performed and offsets calculated and entered into the control, before the tool can run.

The days of throwing worn tools away are over. Because only a small amount of the carbide is actually worn away during machining, inserts and solid tools should be kept as scrap and recycled.

Despite a feeling of general turbulence in the industry, some companies are performing incredibly well. Take Ceratizit UK & Ireland for example which is on track to have its best ever year. Not only that, but the tooling specialist also ended 2023 on a real high with an insanely busy open house in December which saw 150 visitors pass through its doors – one of which was Dave Tudor.

Cost per feature is normally lower with indexable inserts because they have two or more usable cutting edges. Photo courtesy of Walter USA.

According to Mitchell, these shanks offer a dampening effect, which improves roughing performance by enabling a heavier cut to be made. When finishing or an extended reach is needed, it is best to use a carbide shank.

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China, which controls nearly all of the global tungsten trade (roughly 80 percent), has been holding a tight rein on its supply recently to keep the price of this rare-earth metal trending upward. These rising tungsten prices have made tool recycling more attractive and, in some cases, changed purchasing patterns.

Like practically all tooling companies, Ceratizit offers its own tooling cabinet management system called ToolSupply Tool-O-Mat. This is a closed system and is totally managed, restocked and audited by Ceratizit on behalf of its customers. Now however, Ceratizit has introduced a brand new, hot off the press open tool management system called MyTOM. Shaun Thornton explains.

Since its inauguration in 2021, the Technical Centre has been a phenomenal success for both Ceratizit and partner XYZ Machine Tools. It’s used mainly for customer projects, speccing out the right tools for the job in hand.

Because the end mill is screwed into a shank, the shank can be made of different materials to produce different results. For example, for a roughing operation, it is best to use a steel or other heavy metal shank.

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MSC Industrial Supply Co. UK (MSC) is celebrating a successful season after sponsoring two local youth football teams during the 2023/2024 campaign.

“Since we opened the centre, it’s been very busy. Both ourselves and XYZ use the facility extensively and there are always a large number of projects running at any one time. We also use it as a training facility for our staff on new product introductions, our apprentices and even customers. The skills shortage has affected everyone, and we often find our clients need an extra helping hand. For us it’s all part of the service.”

“Over the last 20 years, we have seen a significant increase in recycling all scrap materials, including carbide,” said Nehls. “Customers are savvier with respect to their total production environment, and there is a lot of money in used carbide.”

An interesting aspect of these ISO-P (the ‘P’ denotes performance) inserts is a gold-coloured outer indicator layer so operators can physically see how the tool is wearing in real-time. This forms part of a triple layer arrangement comprising: a Ti (C, N) highly textured base layer; an Al2O3 multilayer; and the gold-coloured TiN outer layer.

“I am delighted to report that Ceratizit UK & Ireland will reach a turnover level of £45m+ this year which represents year on year growth in excess of 15%+,” enthuses Tony Pennington, Ceratizit’s managing director, cutting tools North Europe.

“That’s a lot of carbide … nearly the entire end mill is made of carbide. This is inefficient given the rising cost of carbide and the fact that only 3 or 4 percent of this tool is actually in cut,” said Mitchell. “The same evolution that happened with HSS and brazed tools is occurring rapidly now.”

“Each tool type has its own features and benefits,” said Nehls. “For example, solid drills will typically produce holes to tighter tolerances, perhaps eliminating the need for secondary operations. This makes the solid tool the more economical choice anyway.”

“It’s all about working closely with our customers and making their lives easier,” Mr Thornton affirms. “Sometimes they’ll simply send in a drawing and we’ll work from that; or other times the customer will come here and we’ll work through things together.

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The latest Iscar LogiQuick campaign has unveiled a diverse range of new cutting tools, effectively replenishing the company's portfolio.

“We work extremely hard to provide what we believe to be the best customer service in the industry,” he concludes. “We’ll continue to invest in people and technology to drive the company forward year on year.”

“This product is manufactured by Komet which is part of the Ceratizit Group,” Mr Thornton explains. “Unlike a solid carbide drill, the body holder is steel which offers a degree of flex when machining – and you get full twist drill geometry. WPC holders and inserts are available in a wide range of diameters from 14mm to 30mm and in lengths of 3 and 5xD,” he adds.

“When the customer shows high performance increases, the cost of the carbide becomes less important,” said Nehls. “Ultimately, we are selling cost per feature. When a more expensive tool produces features at a lower cost, the customer is satisfied.”

MyTOM is essentially a separate cabinet that’s linked to a Tool-O-Mat 840 system (it can’t operate standalone) so customers can get the benefits of owning both a closed and open tool management system. Ceratizit takes care of the Tool-O-Mat cabinets; the customer manages MyTOM.

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One of the commodities most affecting tooling suppliers, and the products they manufacture, is tungsten carbide. Over the past decade, tungsten carbide prices have risen sharply. In 2004 alone the price rose 500 percent. According to the Tungsten Investing News, however, the price is not only high when compared to a decade ago, it also has a tendency to fluctuate rapidly.

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You can always have too much of a good thing so Ceratizit doesn’t tend to host open houses often. In fact, the December 2023 event was only the second open house held at the company’s Technical Centre located on the Advanced Manufacturing Park in Sheffield. The first, which took place in October 2021, also marked the official opening of the facility. The common denominators for both events were extremely high visitor interest, loads of product demos and plenty of technology on offer.

“Obviously, since the indexable carbide portion is only a fraction of the size of a solid-carbide tool, the cost to produce this indexable end mill can be much lower,” explained Mitchell. “The true benefits of this technology are not in the cost, but rather in its performance.”

Many years ago high-speed steel (HSS) and brazed-carbide cutting tools were very popular. Today fewer and fewer shops make use of them, with solid-carbide and indexable tooling being the norm. One of the reasons for their waning use is that when a tool is at the end of its life-span, it is taken out of the machine and reground.

At the moment, Ceratizit occupies two sites in Sheffield approximately two miles apart – but not for much longer because the plan is to move both operations to a single site in 2026. Work is already underway in locating a suitable location.

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“Today when an insert becomes dull, we simply index the insert and can expect relatively good repeatability and consistency,” explained John Mitchell, general manager of Tungaloy America. “Insert pressing and coating technologies advanced to where there are now major improvements in performance and chip formation. Few machine shops would want to go back to the days of HSS and brazed cutting tools. However, many shops continue to use solid-carbide tools.”

Machine. Measure. Correct: the Komflex measurement system is a joint collaboration between Ceratizit and measurement and testing technology specialist Blum-Novotest. The system was demonstrated at the open house on an XYZ UMC-5X 5-axis machine.

The premise is the same: Use the tools, take them out of the machine, regrind them, reset the tool, and adjust the offsets. A reground solid-carbide tool will last 80 percent as long as a new tool. In most solid-carbide end mill applications, for example, the end mill takes a conservative depth of cut (0.100 in.), yet the tool may be 3, 4, or more inches long.

“Solid drills have diameters ground to very tight tolerances,” explained Nehls. “When the drilled hole must be precise without additional finishing operations, the solid drill may be the best choice.”

While indexable inserts are certainly the tools of choice in many applications, shops aren’t necessarily choosing them over solid-carbide tools.

For deep hole drilling applications, Ceratizit’s WTX high performance deep hole drills can now drill to depths of 50xD with an appropriate pilot hole. With diameters spanning 2mm to 12mm, the design ensures excellent chip evacuation and alignment precision.

Like, for example, Ceratizit’s new range of ISO-P multi-edged indexable carbide turning inserts with wear detection which were put through their paces on a Mazak Integrex i-250H multitasking machine in the Tech Centre during the open house – a machine that combines turning with 5-axis milling.

New technology has enabled some cutting tool manufacturers to produce indexable end mills, which essentially are small end mills threaded into a shank. Photo courtesy of Tungaloy America.

Rising commodity prices affect every facet of our lives; you only have to look at the price of incoming raw materials and fuel to see this is the case.

“In addition, the further investment we have made in our UK stock to hold over 8,500 lines of our fast-running tools providing a guaranteed next day before noon delivery has given another advantage to our customers. Furthermore, our free of charge vending solutions, providing 24/7 access to tools with full control helps keep our customers’ spindles turning.

I mentioned at the top of this article that Ceratizit UK & Ireland is on track for a record year. The company’s financial year runs from 1st March to 28/29th Feb and for 2023/24 turnover is set to top a staggering £45 million. Remember this is a tooling company – not a capital equipment manufacturer that can sell a machine tool for £1m+. Quite an achievement.

Reground tools have a shorter life, and predictability becomes much more difficult. A tooling “float” also must be created to ensure that tools are on hand when needed.

This is an all-encompassing closed loop boring system that combines production with quality assurance. It comprises a Ceratizit fine boring head which communicates with the Blum’s measuring stylus wirelessly through its RC66 interface, effectively enabling automatic, in-process diameter correction on holemaking and boring processes (6-120mm diameter range). The spindle head and Blum system are initially paired like any other wireless devices.