Sandvik Coromant’s new steel turning insert grade helps THK Rhythm take

control of its machining process - carbide insert grade

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.

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.

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.

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

As you might expect, coating is critical as well. O’Leary pointed to Onsrud’s new ENDURASpeed in-house PVD coating, saying it both adds to the hardness of the tool and increases the tool’s ability to withstand the heat generated during machining. Mickelson referenced silicon type coatings and the carbide tools offered by Hitachi, Union Tool, and Fraisa.

Finishing the part by machining the sixth side you put the dovetail in is usually accomplished by clamping to one of the machined surfaces (e.g., a port face with four bolt holes). But if the part design doesn’t call for such a feature, Mickelson recommended building on a tab with a threaded feature that can be cut off later.

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

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

At the time, Seco had just announced its first Duratomic-developed coating for grade TP2500. "Matt offered us free samples and explained to us how the Duratomic process actually alters the aluminum oxide coating at an atomic level, changing the grain direction to make it more wear resistant," says Roger Stoddard, Tivoly’s design/applications engineer. (For more information about the Duratomic process, link to the article "Atomic-Level Coating Manipulation Adds Durability" under "editor's picks" at the top right of the page).

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.

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

Although advancements in cutting tool technology typically have been incremental, one cutting tool manufacturer says its custom methodology for developing coatings represents a bigger change than the typical new grade or geometry. While toughness and wear resistance are usually considered diametrically opposed, the Duratomic coating process developed by Seco Tools (Troy, Michigan) is said to improve both properties simultaneously. The result? Inserts with both improved cutting capability and prolonged tool life, the company says.

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.

This is also why Mickelson recommended using the option in today’s CAM software that forces a radius on every toolpath when roughing, even at a corner, “because otherwise, a tool cutting a sharp corner can lose enough surface footage to lose the melt. You don’t want any sharp tool paths.”

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.

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

For Dale Mickelson, Yasda product manager at Methods Machine Tools Inc. (Sudbury, MA) and author of several books on hard milling, tackling heat-resistant superalloys (HRSAs) requires the perfect combination of machine, workholding, tooling, tool paths and coolant.

Speaking of compromise, Greenleaf’s XSYTIN-1 is an entirely new type of “phase-toughened” ceramic that does not require full plasticization of the material in order to cut. As a result, you don’t have to run XSYTIN at the same speeds you’d run whisker- reinforced ceramics, though you can. This broadens the applications to larger land-based turbine components that can’t be spun as fast during machining. And the extreme flexural strength of the XSYTIN material also means the micro-geometry at the edge need not be specific to the application, making it easier to select the right tool. XSYTIN tools have just a small brushed A-hone, a simple feature that’s actually “incredibly important,” explained Andersson.

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

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

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

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

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

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

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.

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.

On a machine like the Yasda PX-30i, with 32 pallets in a stacker, the first part is well cooled by the time it comes back for finishing, all without human intervention. Mickelson also recommends zero point fixtures on the pallets to speed the process of re-clamping parts for additional operations or adding new parts.

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

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.

Luke Ivaska, advanced technologies product specialist for DMG Mori, said that by reducing process forces, the system delivers an eight-fold increase in tool life and doubles or triples the surface finish quality (to under 0.1 μm Ra). “We can also improve productivity by two to three times, depending on the specific alloy.”

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.

“You want the smallest possible contact area between the cutting tool material and the material you’re machining to concentrate the heat in this zone,” he said. “But traditional ceramics are brittle, requiring larger, more complex edge prep to withstand the forces generated by machining.”

While there are standard alloys for aerospace, new ones are gaining traction. “For most of the last 15 years, aerospace engines have used pretty uniform materials. Inconel 718 at 46 to 48 Rc is the bread and butter of the industry,” said Greenleaf’s Andersson. And there continues to be huge demand for legacy engine parts, using these same materials. But the latest aircraft engines are designed to work at even higher temperatures and pressures in order to achieve higher efficiencies, and Andersson goes so far as to assert that all these new engines have new superalloys that are much more difficult to machine. “The strategies used for Inconel 718 or 40 Waspalloy are no longer applicable,” he said.

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

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

Mickelson added that when cutting with ceramics, it’s best to deliver air coolant (either through the spindle or externally) for both chip evacuation and cooling, while everyone agreed that high-pressure liquid coolant should be used with carbide tools. High-pressure liquid coolant is also needed for any drilling and tapping.

A grooving attachment enabled Keselowski Advanced Manufacturing to reduce cycle times by over 45 minutes on a high-value, high-nickel part feature.

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.

The primary application for HRSAs is hot zone turbine components for both aircraft and power generation—parts like blades, blisks, brackets, valves, and manifolds, most of which are complex and contoured. That means using five-axis milling to achieve the required forms and tolerances in one clamping. And for smaller parts, solid-carbide round tools are needed, requiring particularly stiff toolholders.

He added that although UTS is not an industry standard, it is “available on every material certification and is used for traceability. UTS is also used by SolidCAM in their iMachining algorithms to develop the cutting tool data recommendations for machining materials.”

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

IN100 and ME16 are two more new nickel-based superalloys that require new tool parameters. ME16 also exemplifies another new challenge: the introduction of powdered metal (in addition to new wrought or cast alloys). According to Andersson, this “significantly changes how it interacts with the machining process.”

Encouraged by the successful application of the grade in the tap blank operation, the team then targeted an M11 tool steel application running on a Mazak SQT200MS CNC lathe. Machining speed was 300 sfm with an 0.003-ipm feed rate and a 0.05-inch cutting depth. Applying the TP2500 grade, again with the MF5 chipbreaker geometry, increased productivity from 40 to 200 parts per edge. "Few initial process changes were required on any of these operations, and depending on the application we realized tool life improvements ranging from 300 to 1,000 percent," Mr. Stoddard notes.

“The key programming technique we look for in Inconel and other superalloys is keeping the tool in the cut as long as you can,” said Mickelson. “Because every time you enter and exit the cut you lose tool life. So we create pocketing routines that move down into the part helically. If you have a flat, you cut down to that flat helically and then finish the flat surface.” The goal with ceramic tools is to “keep the material melt,” as Mickelson put it. Losing the melt and then re-engaging reduces tool life.

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

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

Rob Guiao, Chris Hall and Bassanio Peters will demonstrate relatable situations to equip you with data to improve predictability, future-proof operations and maximize ROI. Agenda:  Explore the importance of data in decision-making, especially for facility upgrades or new projects Learn how comprehensive solutions for manufacturing and construction projects can improve predictability and ROI See real demonstrations of machine integrations, facility layouts and automations to ensure proper throughput and integration

In 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."

The three-prong, crown-shaped MF5 chipbreaker design includes chip deflectors and cooling ditches. According to Seco, these features are beneficial at low depths of cut (between 0.02 and 0.1 inch), while the chipbreaker’s open geometry reduces cutting forces. The manufacturer adds that when used in combination with grade TP2500, tool life often improves by a factor of 10.

A Yasda PX-30i rips through Inconel 718 with a ceramic tool at 3000 sfm, plasticizing the material in order to cut it.

DMG Mori’s Ivaska said “Beta Phase titaniums offer a challenge due to the high molybdenum content. However, with ULTRASONIC we have realized over eight times the tool life at double the productivity.” Finally, Andersson also reported that there are not many new cobalt-based superalloys, though there is a higher degree of cobalt in some new components.

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?

Subscribe to our twice-weekly, free eNewsletter for the latest manufacturing news and technical information, including new technologies, educational webinars, podcasts and more.

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

Fortunately, said O’Leary, “higher transverse rupture strength substrates have enabled us to improve the edge geometry of our tooling, allowing for better chip formation when cutting superalloys. This chip formation leads to greater heat removal and better part finish. Tooling geometry advancements such as variable pitch, variable helix angles, and tapered cores help to create a better cutting tool that minimizes tool vibrations, which are detrimental in machining superalloys.”

The cutting tools used can be carbide, ceramic or other off-the-shelf tooling. And because the ultrasonic head can be changed out automatically, tools of different types can be combined on the same part. In one case study, DMG Mori reported that the complete machining of an Inconel 718 turbine blade from a raw block, using ceramic and carbide end mills, took 23 minutes versus 32 minutes for conventional machining.

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.

Finally, after a roughing process that’s literally melting the surface of the superalloy, it’s important to let the parts cool before finishing. Mickelson’s preferred approach is to rough the whole part, without pulling it out of the fixture, then rough additional parts in sequence before switching to finishing.

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

Another key to success, however, is a focus on partnerships with both customers and suppliers—suppliers like Seco, which provides more than 50 percent of the company’s cutting tool needs. In 2006, as part of its commitment to progress, Tivoly began a formal process-improvement/cost-reduction initiative in collaboration with Seco technical specialist Joe Mecus and Seco distributor Matt Murray of Blanchard Industrial Supplies. The two visited Tivoly weekly and spearheaded monthly meetings between the two companies to assess machining operations and decide where productivity gains or cost savings could be achieved most easily.

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

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

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."

Similarly, Mickelson said that cutting 3D-printed Inconel is much different than cutting standard Inconel. “It seems more like a CPM material or a hardened steel than an Inconel. It seems harder and more abrasive. We’d use ceramic cutters but with slightly lower surface speeds and a light chip load.”

Finishing superalloys requires carbide tools with special geometries and high precision, like variable helix and unequal indexing, as shown in these LMT Onsrud designs.

Coincidentally, Mickelson is now testing a system that blasts dry ice (CO2) into the cutting zone. Called DIPS (Dry Ice Powder Cooling System), it promises to deliver greatly improved tool life but it’s too early to say if it meets expectations.

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.

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

Finally, XSYTIN is now available in ballnose end-mill configurations. That’s not new for ceramics, but before XSYTIN users have been forced to tilt ceramic ballnose tools to keep the end out of the cut since sfm goes down to zero at the center of a ballnose. (Remember that ceramic requires a high sfm to cut.)

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

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

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

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.

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.

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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Cutting HSRAs at any speed generates temperatures too high for normal tungsten-carbide substrates, explained LMT Onsrud’s O’Leary, adding that “the running environment is also quite abrasive since there is a significant amount of carbide precipitates that are present to the alloy.” Even with finishing at 100 sfm, you can’t use standard carbide tools for these materials.

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.

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.

For carbide tools, James O’Leary, process improvement specialist, LMT Onsrud (Waukegan, IL), recommended hydraulic or heat-shrink chucks that “can maintain a runout of ≤0.0002″ (0.005 mm) at a length of 4X the tool’s diameter.” But heat-shrink holders won’t work for ceramic tools, explained Mickelson, because they run at such high temperatures that the heat affects the hole in the holder. For ceramics, he recommended collet holders.

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.

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.

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.

DMG Mori USA (Hoffman Estates, IL) has introduced an even stranger innovation for machining superalloys than cryogenic cooling: rotary ultrasonic machining. The device is an ultrasonic actuator added to a machine tool’s standard HSK spindle that oscillates the tool axially as it’s spinning. The degree of oscillation can vary between 0 and 10 μm, depending on the application, and the system automatically adjusts the ideal resonant frequency of the oscillation based on real-time feedback. Because the technology is scalable across platforms, the tool can spin as high as 50,000 rpm during ultrasonic machining on the ULTRASONIC 20 linear model.

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.

Both Mickelson and O’Leary pointed to dovetails as the preferred method to hold Inconels and other superalloys so as to minimize part movement and deflection. The idea is to cut a dovetail into the raw stock and then use dovetail vise jaws to hold the part. “It doesn’t require a lot of material, which is important with such high-cost alloys,” explained Mickelson, “but you can get by with a small amount of hold.” And as O’Leary explained, “holding the part with a dovetail provides free access to the side of the material in a horizontal or five-axis machining environment.”

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 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.

DMG Mori’s ultrasonic actuator oscillates the cutting tool axially as it’s spinning, improving tool life, surface finish and material removal in superalloys.

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.

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

5ME (Cincinnati) has published data showing improvements in material removal rates, tool life and surface finish when cutting Inconel 625 with its liquid nitrogen cryogenic coolant system (see “Deep Freeze Helps Cuts Challenging Materials,” ME, Dec. 2017). But while Inconel 625 is commonly used in the oil and gas industry, there appears to be little published data with cryogenic cooling on the Inconels used in aerospace, according to Johnston.

In any case, it’s wise to pay attention to the details and seek out experience. As Andersson related: “We work closely with the OEM research facilities and other R&D centers, cutting materials that are not yet introduced. It’s very common for us to get phone calls from people claiming to have materials no one has ever machined before and we can give them exact cutting data because we have machined it in our R&D facility.”

O’Leary added that LMT Onsrud’s EMC and MaxQ end mills are manufactured with newer CNC grinders, “which have given us the ability to maintain a higher degree of control during flute grinding on these tools and to achieve tighter tolerances in the flute’s geometric relationships.”

This claim is born out by the experience of Tivoly, a close partner of Seco. This Derby Line, Vermont-based shop recently acquired the capability to cut more aggressively, reduce cycle times, and reduce per-part and tooling costs by 20 and 70 percent, respectively—all without any major changes to its manufacturing processes. Rather, the lion’s share of the credit for these productivity gains went to the first Seco insert grade to incorporate a Duratomic-developed coating. "Without Duratomic, improved cost through cycle time reduction would not have been possible unless we made a big investment in capital equipment and totally revamped our processes," says Scott Gowdy, Tivoly plant manager.

Mickelson said his testing shows that BIG Plus chucks deliver twice the tool life of comparably sized HSK systems (e.g. BIG Plus 40 versus HSK 63A). However, Lee Johnston, applications engineer, Okuma America Inc. (Charlotte, NC), said similarly sized HSK systems are “slightly more rigid” and “in theory, you can push the tool a little harder.” He added that the bigger HSK 100 or 125 systems (for which there are no comparable BIG Plus spindles) would be even better because you have more pullback force in addition to the face contact.

Exchanging turning inserts for Seco’s Duratomic-coated grade TP2500 helped this manufacturer reduce per-part and perishable tooling costs by 20 and 70 percent, respectively.

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).

Few companies can trace their heritage as far back as Tivoly, which got its start manufacturing a cutter designed to restore worn wagon axles in 1880. The company evolved into part of the Union Butterfield Corporation until it was sold to French-owned Tivoly Inc. in 1989. Today, its product range includes hand taps, production taps, performance taps, application taps, carbide taps, specials, reamers and drills, many of which are private-labeled for other cutting tool manufacturers. The company says one key to its corporate longevity is a focus on progress that incorporates a commitment to continous improvement and a recognition that change is necessary and inevitable.

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

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.

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.

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.

Seco's Duratomic-grade inserts are said to run faster and longer than competitive models. Key to their performance is a unique texture achieved by manipulating the coating at the atomic level.

The new inserts’ predictable performance and suitability for a variety of materials contributed to additional cost savings. That’s because the company no longer had to devote significant engineering and programming resources to change cutting parameters for thousands of different parts in small lot quantities. Combined with the cycle time reductions, this reduced per-part costs by 20 percent.

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

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

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.

A set of donated boring bars that can be used in a 1954 boring head will enable volunteer machinists to recreate a pair of binoculars for the USS Pampanito.

Mickelson is also the first to say you can’t cover everything in an article, or even a book, and he has been asked to cut his drafts in half to meet the practicalities of publishing. But let’s review some highlights.

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

Take a new material called Inconel 718 Plus. “It sounds very similar to 718 but it machines completely differently. I would say Inconel 718 Plus differs from Inconel 718 more than Inconel 718 differs from Inconel 625. The OEMs and the Tier 1s are very much aware of this. But when you get farther down the Tier scale into contract manufacturers and people bid on a job for 718 Plus as if it were 718, they soon find out they’re about to lose their shirts.”

The speeds involved might surprise you. Mickelson said he generally uses Greenleaf whisker-reinforced ceramics at 3000 sfm in Inconel 718, but with a very light chip load. For a 2″ (50.8 mm) diameter insert cutter, 3000 sfm works out to about 5700 rpm, which is in the high-torque range of a machine he’d commonly recommend, the Yasda PX-30i. “But ceramic inserts don’t require high torque because the chip load would be only two thou per flute in this example.” For finer contouring on something like a blade, you’d probably want to rough with a smaller solid-ceramic endmill, which means even faster speeds. For example, a ¾” (19-mm) end mill would have to run at over 15,000 rpm to achieve 3,000 sfm. So machines like the Okuma Blade T400 or the Yasda PX-30i have 18,000 and 20,000-rpm spindles, respectively.

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.

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

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!

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.

Speed and torque for HRSA machining: The Okuma five-axis BLADE T400 features a 38-kW motor and an HSK-A63 spindle running at up to 18,000 rpm.

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.

However, improvements stemming from the use of the new grade didn’t end there. Mr. Mecus offered suggestions on standardizing Tivoly’s carbide tools in order to reduce the large number of different inserts it kept in inventory. As a result, annual consumption of turning inserts decreased from 751,200 to 1,252. This reduced spending on perishable tooling by approximately 70 percent.

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.

Conversely, ceramics don’t deliver the required surface finish for most HRSA parts, so you’re forced to switch to carbide tools running at completely different feeds and speeds. Mickelson said you’d run carbide at 100 sfm in Inconel, with a 10 to 15 thou chip load. That means much more torque at a much lower speed. So as Johnston put it: “The machine configuration can be a compromise. It’s hard to get the best of both worlds.” Not to be left out, Andersson said that for “non-critical components, which are typically non-rotating, ceramics are suitable for finishing as well, especially our WG600 coated ceramic.”

“Because of the strength of the XSYTIN material, you don’t have to do that, which makes it much easier to apply.” This issue may help explain an interesting point raised by Johnston: that when machining with ceramics, the amount of material left is less predictable with end milling than it is with face milling.

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.

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

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

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

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

Designed for general steel turning applications, TP2500’s functionally graded substrate structure is said to increase edge toughness without sacrificing strength for the bulk of the material. The first test at Tivoly involved turning an 0.05-inch standard tap blank in M1 tool steel. For this application, the company had run indexable inserts on a Citizen L25 Swiss screw machine at 600 sfm, a feed rate of 0.005 ipm and a cutting depth of 0.06 inch to achieve 150 parts per cutting edge. Applying the Duratomic-coated TP2500 grade with an MF5 chipbreaker geometry improved the process to 1,500 parts per cutting edge—without changing any of the original cutting parameters.

There is wide agreement that ceramic tools are the best option for roughing HRSAs. And with ceramics, as Jan Andersson, global manager, TechTeam & marketing, Greenleaf Corp. (Saegertown, PA), explained, “the first step is setting the right speed to raise the temperature in the cutting zone to create a certain degree of plasticization of the material, making it easier to machine. Otherwise, you struggle with unpredictable tool life. After determining the appropriate speed, you use feed rate to manage thermal evacuation. The higher the feed rate, the more mass in the chip. The more mass in the chip, the more heat you transport away from the cutting zone. That controls the chemical wear component.”

O’Leary said it is beneficial to understand the material’s ultimate tensile strength (UTS) and heat-treating condition ahead of time in order to determine the best operating parameters. “If you’re altering tool operating parameters for each material batch, it is probable the new material has a different heat treat and UTS. A good practice is to chart the UTS of each material you bring into the shop. This will assist in attaining solid operating parameters that will be successful at each UTS/Hardness range.”

The small XSYTIN hone concentrates the heat in a smaller zone, making the material easier to machine and also introducing less force on the material. Another big payoff: You can run it at the same speed as whisker-reinforced ceramics, while using feed rates that are 50% to 100% higher, increasing productivity by 50-100%.

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.

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

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

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

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

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.

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

Andersson added that other applications calling for XSYTIN are forgings and castings with skin and scales. “That kind of surface is very difficult to machine, but the flexural strength of XSYTIN allows you to do so at high levels of productivity and predictability.”

Like titanium (see “New Ideas Give a Jolt to Titanium Machining,” ME, January 2018), machining HRSAs requires a very stable machine, rigid workholding and a very stiff interface between spindle and toolholder. And like our earlier discussion on titanium, “the jury is still out on the ideal implementations of these requirements.

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

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.

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

Tivoly’s TP2500 inserts incorporate the three-prong, crown-shaped MF5 chipbreaker design, which includes chip deflectors and cooling ditches. According to Seco, the chipbreaker can improve tool life by a factor of 10 when used with this grade.

Get sensible, real-world automation solutions during this half-day workshop co-located with IMTS 2024.

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

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.

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

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

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.

Sometimes, nearly everything has to change: feeds, speeds and tool geometries. “It’s not uncommon to have to go from a negative rake to a positive rake insert. In some materials it’s the opposite,” said Andersson.

Tivoly manufactures various types of taps and other tool components. The parts shown here, which are part of a thread-repair kit for taper-seat and gasket-type spark plug assemblies, have been roughed using Seco Duratomic turning inserts. The parts have yet to undergo threading and grinding operations.

That said, perishable tooling represented only a small piece of the production cost pie. The company realized greater benefits through cycle time reductions. Although initial tests used the same feeds, speeds and cutting depths as previous tools, the company soon found that the Duratomic-coated TP2500 grade enabled it to overcome previous limitations on these parameters in some applications. Cutting more aggressively—often to the point of maxing out the capability of a given machine—reduced cycle time on roughing operations by 50 to 80 percent, approaching speeds ranging to 1,500 sfm in tool steel operations that previously ran within the 500 to 700 sfm range.

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

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