Overcoming the Interrupted-Cut Blues - best carbide insert for metal lathe

 2024-06-27 18:12:30

Using a completely solid holder means that even a very small discrepancy will cause high axial forces on the flanks of the threads. “This has a negative effect on tap life and thread quality,” said Johnson. “Using a tap holder with a small amount of axial compensation allows the tap to better follow its pitch and this reduces the axial forces for a dramatic improvement in tap life and thread quality.”

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When selecting a substrate, several machining factors are critical, such as torque, thermal stability and wear factors. A powdered metal HSSE-PM substrate, for example, offers added wear resistance for better quality tool edges.

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.

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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

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.

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.

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.

LOGIQ3CHAM is designed for carbon and steel materials ISO P and ISO K cast irons and nodular irons. It can increase productivity by up to 50 percent when compared with common two-flute drills with exchangeable heads, according to Iscar. Concave cutting edges enable smooth penetration into the work material, as well as excellent centering and stable drilling. Features include a durable drill body made from a hard, high-strength steel grade for better wear resistance. Polished flute surfaces ensure smooth, easy chip evacuation,, and dovetail clamping prevents the drilling head from being extracted from the drill pocket during retraction, according to the company.

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

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Advanced technologies used in Iscar USA’s two-flute SUMOCHAM exchangeable head drilling line form the basis for the design of its three-flute LOGIQ3CHAM exchangeable head drill line. “When you think of a hole, it seems to be very simple—just a radius projected into a third dimension. But it’s a common feature that is used for producing products in job shops and high production environments, like automotive. [It is also common in] high-precision applications like die mold, medical and off-road industries,” said Craig Ewing, national product specialist-drilling for Iscar USA, Arlington, Texas.

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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.

Combination tools are versatile, as this selection from GWS suggests. “Each tool has its own story and problem it solved,” said Strauchen. “One drill creates three steps within the part with mirror finishes. Another is a four-step high precision reamer with 45˚ coolant ports in each flute. This design maintains tolerance within 2 μm and finish under 8 RMS.”

The unique pocket design of the SUMOCHAM drill takes advantage of the cutting forces that are mechanically exerted upon the tool. These forces are converted into gripping forces used for tightening the insert towards the back of the pocket—the more cutting forces applied, the better gripping forces obtained.

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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

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.

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

For example, in one test using rigid tapping to tap ten M8 holes at 2,500 rpm, cycle time was 18 seconds. Repeating the same test at 4,000 rpm saved just one second. Using a self-reversing tapping attachment at 2,500 rpm to tap the same ten M8 holes took just 11 seconds. “In addition to improving cycle time, using a self-reversing tapping attachment also allows the tap to run at the recommended speed, and this provides longer tap life as well,” said Johnson.

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“The tool was designed for a highly abrasive, high-silicon aluminum component. The tool’s geometry combined a counterbore, chamfer and drill in a one-step tool that eliminated costly cycle time,” Strauchen said. “Previously, the process required three operations, three tool changes and inventory management of three different part numbers. The three-flute, high-shear design features coolant passages behind each cutting edge to maximize feed as well as super-polished flutes to further improve chip evacuation. Feed rates in this application exceeded 300 ipm.”

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

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.

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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.

Threading a hole is one of the last critical production steps and having the right tap is critical for avoiding part rework or even scrapped parts, according to Mark Hatch, product director, Emuge Corp., West Boylston, Mass. “When working with materials such as steel alloys and iron, there are a broad range of complexities to address for proper tap selection,” he said. “When tapping alloyed steels, [there are] variations in chip shape, size and length due to variables in chemical properties and heat-treatment. The type and percentage of each chemical element, in conjunction with heat treatment, combine to produce different mechanical properties which affect machinability. When choosing a tap for the application at hand, factoring in the tap substrate, coating and geometry is key. “

For coating, YG-1 has developed a post-coat treatment for its proprietary H coating that aids chip evacuation in deep-hole drilling. “The treatment smooths out the peaks and valleys that result in coating. We found that we can pick up about 20 percent more tool life by applying polish to inserts, insert tips and normal sized drills,” Pilger said. “For deep-hole drilling, high-pressure coolant delivery on machining centers has enabled shops that 15 years ago were forced to gundrill parts at 1-2 ipm on dedicated gundrill machines. Now they can process the same deep holes on CNC machining centers at 20 to 30 ipm.”

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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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.

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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:

Successful tapping applications depend on several important factors. These can include axial compensation on CNC machines, internal coolant supply, and special advantages related to self-reversing tapping attachments, according to Mark Johnson, president of Tapmatic Corp., Post Falls, Idaho. “Rigid or synchronized tapping on CNC machines has become an industry standard,” he said. “Even though the synchronization of the machine’s feed advance to the spindle rotation is accurate, there will always be a small discrepancy between the actual pitch of a specific tap and the machine’s synchronized movement.”

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Tool geometry is a key factor for the efficient threading of steel alloys. Choosing a straight flute or a spiral flute such as low helix angle (slow spiral flute) or high helix angle (fast spiral flute) will depend on the machinability of the material—how hard it is and its heat treatment. The choice directly affects the chip produced and the tap chosen for the job. If the material is annealed, a long chip will be produced and a high spiral tap may be a good option. However, as the steel hardens, this type of tap may break.

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

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 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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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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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.

In the late 1800s, a new technology — Swiss-type machines — emerged to serve Switzerland’s growing watchmaking industry. Today, Swiss-machined parts are ubiquitous, and there’s a good reason for that: No other machining technology can produce tiny, complex components more efficiently or at higher quality.

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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.

He also described a large brazed-carbide reamer with staggered coolant ports in each flute. This brazed-carbide reamer features an independent rotating plunger designed to detect blind or undersized holes. It detects these holes by compressing when meeting an obstruction and blocking coolant, which stops the machine prior to the tool breaking.

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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.

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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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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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.

SUMOCHAM exchangeable head drills offer a variety of styles for the common alloy steel applications, said Ewing. “They are available in 1.5D, 3xD, 5xD, 8xD and 12xD depths for typical machining center applications with CAT 40 and 50 shanks, HSK, CAPTO, live tools in lathes and for use in multifunction machines like the Mazak Integrex,” he said.

LOGIQ3CHAM is a three-flute exchangeable head drill line available in diameters from 12 to 25.9 mm (0.472-1.020") diameters. Drill bodies come in 1.5xD, 3xD, 5xD and some of the sizes in 8xD. The extra flute enables higher feed rates to be obtained, which increases productivity. “We’re seeing the third flute as being more beneficial in high-production applications as well as increasing tool life,” said Ewing.

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.

Pairing a shoulder mill with a five-axis machine has cut costs and cycle times for one of TTI Machine’s parts, enabling it to support a niche racing community.

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.

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.

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.

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Drew Strauchen, executive vice president, GWS Tool Group, Tavares, Fla., noted that part of the evolving trend in holemaking (and metalworking in general) is the customization of holemaking solutions to more perfectly fit the customer’s exact application while minimizing operations. “Being able to pick the best substrate, geometry, coating, and tool lengths for the shop’s specific application is paramount to more manufacturers looking to compete in a global market. Along with customization is combining two or more tools to further reduce operations and cycle times—the very definition of optimization,” he said.

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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.

Steel applications are also benefiting from three-flute drills for a number of reasons, according to Strauchen. Formerly used effectively just for aluminum applications, three-flute drills are becoming increasingly popular for materials like cast iron and steel. “New flute forms married with coolant-through technology have expanded the capability for ferrous materials. Adding the latest in ultra-smooth PVD coatings and integrating reverse web tapers has further enhanced our capacity to produce drills that optimize productivity while ensuring stable chip evacuation,” he said.

SUMOCHAM, which is available in diameters ranging from 4 to 32.9 mm (0.157 to 1.295") in 0.1 mm (0.004") increments, offers a variety of edge preps for various carbon and alloy steels, as well as high-temperature steel alloys and stainless. SUMOCHAM features a clamping system that enables improved productivity output rates, while enabling more insert indexes. The shank itself is designed with twisted nozzles and has a durable and stably constructed body. The indexable heads are available in ten different standard geometries designed for drilling steel, exotic materials, cast iron or aluminum, according to the company.

After experiencing process stalls in the finishing stage of production, Bryan Machine Service designed an air-powered twin spindle and indexable rotating base to effectively double its production of small parts.

For short chipping hardened steel and cast iron, Emuge A-H Taps are a new generation of Premium HSS-E and HSSE-PM taps that are especially efficient for tapping abrasive materials and materials with high hardness levels, such as cast iron, common in the heavy equipment and agricultural vehicle markets. Emuge A-H Taps are available with or without coolant through holes and with TiCN coating, or NT nitride surface treatment, for improved tool life.

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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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.

Innoform-Steel-M Taps feature polygon geometry for low torque and longer tool life. A special powdered metal substrate and a TiN-66 coating with increased hardness reduce friction and extend tool life. Innoform-Steel-M Taps are recommended for forming cold-extension steels, cementation steels, castings, heat-treatable nitriding and cold work steels, as well as high-alloyed and hot work steels.

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YG-1’s premier product is the Dream Drill solid-carbide drill, according to Pilger. “Dream Drills maximize tool life and chip evacuation when running cast irons and steels,” he said. “For example, for steel applications to perform at the most efficient feeds and speeds, a split-point style drill might be recommended, while for a stainless steel you might use a more positive four-facet style.” Dream Drills are available from 1-20 mm diameters in 3xD, 5xD and 8xD lengths. YG-1 also offers them in 10xD, 15xD, 20xD, 25xD and 30xD extra-long drills, all from stock. “Some customers are changing how they run some steels like 4140 alloy steel. They want to process high quality parts at high production rates,” said Pilger. “They need higher speed cutting, taking the average 350 to 450 sfm to produce the highest quality parts and achieving the longest tool life.” For these high-production, high-volume environments, YG-1 offers the Dream Drill Pro line for alloy steels and cast-iron auto parts.

It’s fair to say that holemaking accounts for the largest share of machining both in small shops and large production facilities today. And the bulk of that holemaking is drilling in steel and cast iron up to 1" (25 mm) in diameter. What is driving drilling and tapping performance are advances in substrate, coatings, three-flute designs, and combination tools. Just as important are advances in coolant delivery, using different size holes and shapes to facilitate chip evacuation.

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

Over the past five years, Hatch points to improvements in tap tool life and process consistency due to improved tool coatings. “Emuge has developed optimized coatings that are designed for excellent thermal stability, wear resistance and a low friction coefficient. Because coating adhesion on taps can be challenging due to the tools’ peaks and valleys, Emuge has engineered coatings that are precisely distributed across surfaces and will stay put,” Hatch said.

Lubrication is important for tapping in general and especially for roll form tapping. “Using a tap holder with internal coolant capability allows the use of taps with either an axial coolant hole for blind holes, or radial coolant holes for through hole applications,” said Johnson. “This gets the coolant where it is needed for the cutting or forming of the threads. It also greatly helps with clearing chips out of the hole when using cutting taps.”

Manufacturers have good options in both roll forming (chipless production of internal threads) and cutting taps. For example, Emuge offers Innoform–Steel-M, a line of HSSE-PM taps for forming threads with improved surface quality, while increasing static and dynamic thread strength, in medium strength steels up to 44 HRC.

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.

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.

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.

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.

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

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.

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.

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

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In this webinar, 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

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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The CBTz tap is surface treated with TiN to reduce friction between the tap and workpiece, which results in improved thread finishes and increased tool life in carbon and alloy steels, cast and forged steels, tool and die steels and 300 stainless steel up to 35 HRC.

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.

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.

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.

Tapmatic’s SynchroFlex tap holders all include a balanced, high-pressure internal coolant system. Pressure up to 80 bar or 1,200 psi can be used and because the system is balanced, the coolant pressure does not influence the tap holders axial compensation.

You might be able to use some of the recent developments described here by several leading toolmakers.

Tapmatic’s SynchroFlex tap holders include a machined flexure that provides a small amount of axial compensation. “The SynchroFlex flexures have a high spring rate, which is important for avoiding axial miscutting,” he said. “If the spring force is too soft, like in the case of traditional tension-compression tap holders with a large amount of axial compensation, axial miscutting can occur. This is especially true when using free-cutting, high-speed taps often recommended for synchronized or rigid tapping cycles. SynchroFlex is designed to provide just the right amount of compensation for synchronized tapping.”

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

YG-1 USA, Vernon Hills, Illinois, is a full-line supplier not only of holemaking tools but also of carbides, round tools and inserts as well as high-speed steel, powdered metals and cobalt. It produces some 60 million round tools a year, according to Steve Pilger, national product manager, holemaking. “We service our customers with the latest CNCs as well as legacy Bridgeports. The holemaking challenge for shops is to make a higher quality product and make it in the shortest time possible to the highest tolerances with tools that have superior life and application capabilities,” said Pilger.

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

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

For drilling steel and cast iron where flexibility is valued and the highest speeds and feeds aren’t required, YG-1 offers the I-Dream Drill General line, which offers versatility in drilling steels, carbon, alloy, and cast irons.

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.

When long chips are the challenge, taps are available with cutting face geometry and spiral flute form, which combine to affect chip flow, chip curl and chip length. Emuge chip-breaking technology (Emuge CBTz) produces short, broken, controllable chip formations that eliminate flute clogging and potential failure of the machine tap due to chipped cutting teeth or breakage, according to the company.

In addition to implementing new advancements in technologies, GWS Tool Group is designing combination tools that permit customers to perform multiple drilling operations with one tool, instead of two, three or sometimes even four tools. “Being able to tailor a tool for a specific application is critical for reducing operations and cycle times,” said Strauchen. He supplied an example of a combination tool developed for an electric car manufacturer.

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

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

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

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.

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

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

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.

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

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.

The number one challenge of drilling with three flutes in steel is getting the chips to evacuate through a flute volume that naturally gets smaller with the addition of the third flute. “Aluminum chips are softer and more malleable so they can be ejected out of the hole even if the chips are longer,” Strauchen said. “Steel chips, on the other hand, are far less forgiving if not broken and controlled adequately. With the addition of a third flute it’s critical to produce small chips (6’s and 9’s) to ensure stable, consistent results.”

The newest addition to YG-1’s drill lineup is the I-ONE modular interchangeable head drill, available in 3xD, 5xD and 8xD lengths. The steel body offers flexibility and can hold five or six different size inserts cutting from the same flexible steel body. I-One offers the advantages of a carbide drill with flexibility of a steel body.

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

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

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

Self-reversing tapping attachments offer special advantages compared to synchronized tapping. “With synchronized tapping, because the machine spindle needs to stop and reverse within a very limited number of revolutions, it is not possible for the machine to maintain the programmed spindle speed. Using a self-reversing tapping attachment allows the machine spindle to turn continuously in one direction at the actual program speed. The result is a shorter cycle time,” said Johnson.

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.

The substrate was ultra-fine grain carbide with reduced cobalt content to reduce the possibility of built-up edge. The tool coating was a material-specific ALU coating that extends tool life while maintaining sharpness.

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

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