Rushing machining with versatile indexable Maxi-Rush solid carbide heads - carbide end mills

 2024-06-24 11:25:51

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

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.

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.

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

Recent internal testing with the new Harvi Ultra helical milling platform achieved over 100 minutes of tool life running at 47m/min with a 0.12mm/tooth chip load. The radial depth of cut was 25mm and the axial depth of cut was 76mm.

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

The lack of skilled labor is also a broad-based issue and, as readers of Modern Machine Shop know all too well, particularly acute in the United States. That is creating demand for more sophisticated machine tools and automation to reduce the labor required to manufacture goods. While this class of equipment does represent a growing portion of the mix of manufacturing technologies, it is more expensive and takes more time to build. Though many of world’s major machine tool builders did see a modest downturn in 2022, average backlogs remain relatively high.

Called KCSM40, the company has taken the toughness of its most popular milling grades KC725M and X500, and increased the thermal crack resistance and wear resistance that will enable customers to machine at higher cutting speeds, without sacrificing that original toughness.

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.

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.

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."

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.

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.

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.

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

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.

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.

Kennametal has responded to requests for a new carbide grade to machine titanium 6Al4V at higher cutting speeds, rather than increasing feed rates or increasing depth of cuts that result in increased cutting forces on the workpiece, fixtures and machine spindles.

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.

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

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

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.

For more information contact Kennametal South Africa on TEL: 011 748 9300 or visit www.kennametal.com

The grade has an advance cobalt binder that provides exceptional thermal fatigue resistance, without sacrificing the toughness customers have experienced with KC725M or X500. In addition, Kennametal’s proprietary AlTiN/TiN coating enhances the wear resistance at the cutting edge.

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

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

Inflation was another factor affecting the world manufacturing industry. According to the IMF, the global inflation rate was 8.8% in 2022, the highest level since 1982. This, in combination with the war in Ukraine, drove energy prices to the highest levels in years. Oil prices rose to $139 per barrel in March, the highest in more than a decade, and natural gas prices in Europe rose to a record high in December. All of these factors contributed to increasing delivery times and prices for machine tools, regardless of country.

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

China was also the world's number one consumer of machine tools at $27.4 billion. The United States came in second by a very large margin at $10.1 billion. They were followed by Italy ($5.7 B), Germany ($5.5 B), Japan ($4.0 B)South Korea (3.1 B), India ($2.8 B), Russia ($2.1 B), Mexico (2.0 B) and Taiwan ($1.8 B). China also remained the world’s top machine tool importer, followed by the US, Germany, Mexico and Italy.

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.

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

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!

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

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

Manufacturers continue to feel the pressure to reduce costs, increase efficiencies and meet their sustainability strategies. As the industry evolves to keep pace with these priorities, there are opportunities within metalworking processes to use less resources with advanced lubricants and technical expertise. Agenda: An overview of metalworking lubrication Evolutions in metalworking lubrication Experience on the shop floor Key takeaways

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

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.

As expected, world machine tool consumption followed a very similar pattern. There were bright spots, however, with three of the top 10 consumers posting gains: Italy grew its machine tool consumption by 11.7%, India by 30.3%, and Mexico by 11.5%.

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.

issues last year, machine tool production fell some 10% and consumption some 9% across the top 50 industrialized countries in 2022. Specifically, overall machine tool consumption decreased from $87.3 billion in 2021 to $79.5 billion in 2022 while production decreased from $92.1 billion in 2021 to $82.6 billion in 2022. Though the drop was significant, 2022 nonetheless was a solid year for the machine tool industry. According to AMT – The Association for Manufacturing Technology, 2022 was the third-best year on record for new orders for machine tools in the U.S.

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.

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.

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

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 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.

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.

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.

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

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

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

Of the top 10 machine-tool-producing countries, only India and Brazil posted year-over-year gains at relatively modest increases in real dollars (adjusted for currency exchange rates and inflation) over their 2021 levels. Expanding to the top 20 machine-tool-producing countries, Russia also reported modest gains. Of the top 10 machine tool producing countries, the U.S. saw the largest drop at about 24%.

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

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).

“The edge condition on the KCSM40 grade still looked great. And we are getting many other fantastic results. In one face-milling operation on a hardened steel wear plate, the number of passes was reduced from 234 to just 22,” said Etling.

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.

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

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

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

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

Modern Machine Shop is the leading publication and media brand in North America devoted to CNC machining. MMS combines unprecedented editorial access to manufacturing facilities with decades of experience to provide long-form content that is both insightful and impactful. About Us

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

These data come from the annual World Machine Tool Survey conducted by Gardner Business Media (publisher of Modern Machine Shop). Each year the Survey ranks the world’s top countries in machine tool production, consumption, imports and exports. For the ranking, the Gardner Business Intelligence team takes reported or estimated machine tool economic data and adjusts for exchange rates and inflation which enables year-to-year comparisons in real dollars.

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.

There was little change in the order of the world’s top 10 machine tool producers and consumers from 2021. Leading the list of producers was China at $27.1 billion. According to a report issued by ISO in 2021, a little over three-quarters of Chinese production then was in CNC machines. Second place in 2022 machine tool production was a near tie between Japan ($10.5 B) and Germany ($10.3 B). They were followed by Italy ($6.9 B), the United States ($5.9 B), South Korea ($4.5 B), Taiwan ($3.9 B), Switzerland ($2.6 B), India ($1.4B) and Brazil (1.0 B). The world’s top exporters, in order, were Germany, Japan, China, Italy and Taiwan.

The target cutting speed for KCSM40 in Ti6Al4V was 53m/min at 327cm3/min 327 metal removal rate for 60 minutes. Not only does KCSM40 achieve this, but has also offered milling titanium at speeds up to 85m/min at a lower radial depth of cut.

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.

One of the more striking observations about the 2022 World Machine Tool Survey is how consistent the production and consumption numbers were globally. Typically, there are more changes among the rankings due to varying conditions in regional manufacturing economies around the world. However, last year virtually all industrialized nations faced very similar challenges. There were the lingering effects of the Covid-19 pandemic which continued to impact supply chains everywhere. While supplier deliveries did improve over the course of the year, key shortages continued to hamper production, particularly in electronic components.

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

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

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

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

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.

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.

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?

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.

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

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

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

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.

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

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

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

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

This is the 55th edition of an independent, annual survey that collects statistics from machine tool consuming and producing countries and compares them in real U.S. dollars. It is conducted by Gardner Intelligence, the research department of Gardner Business Media Inc. (Cincinnati, Ohio). Criteria for inclusion in the report are: 1) a country has imported at least $100 million of machine tools at least one year since 2001; and 2) country data are provided or reasonable estimates can be calculated. Data are reported for 52 countries in the 2022 report. Total import, export, and production data are provided by, or estimated for, each country. Consumption is calculated by adding imports and production, then subtracting exports. The data typically are reported in local currencies, then converted to U.S. dollars. Historic data are adjusted for inflation using the U.S. Bureau of Labor Statistics’ Producer Price Index for capital equipment. This adjustment promotes more accurate comparisons over time.

Says “At higher radial engagements, the insert is cutting the material for longer time which creates more heat at the cutting zone. The heat will not go into the titanium chips, like when milling steels, so controlling the heat is critical. Lower cutter speeds at higher radial engagements is a good practice. At lower radial engagements, higher cutting speeds can be achieved,” said Scott Etling, director of global product management for Indexable Milling at Kennametal.

For countries that do not report total imports and exports, data from the International Trade Centre (ITC) are used. ITC data are also used to report imports and exports at the machine tool category level for all countries. Estimates are calculated for production when data are not provided. Imports and exports at the machine tool category level typically sum to numbers less than or equal to the corresponding totals reported. Differences are driven by reporting the top 5 rather than all 8 machine tool categories. In rare instances, imports and exports at the machine tool category level sum to numbers higher than the corresponding totals reported, likely a function of the machine tool category level data including parts and components that are not included in totals. It can also be an artifact of using different data sources.

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

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

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.

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

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.

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

While global machine tool activity slid back to 2020 levels last year, overall production and consumption were still at historically healthy levels.

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

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

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.

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.

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

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

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.

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

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

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.

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.

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

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.

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.

Rushing machining with versatile indexable Maxi-Rush solid carbide heads - carbide end mills

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