Forming Taps - forming taps

2024-10-17 22:45:28

A combination of lasers, probes and software help moldmakers automate in-process cutting tool and workpiece measurement.

Rough milling operations can take hours on large components and typically remove more than half the raw material by volume. Selecting the proper machining method for the component and machine tool creates a successful and stable system. The use of plunge roughing, commonly referred to as plunge milling, has grown recently as cutting tools that can handle the tough requirements of this machining method have become more readily available.

For drill stability, the machine, fixturing, tool and toolholding must be considered as one connected system. From a tool standpoint, the goal is to have as stiff of a drill core or web as possible and still be able to smoothly evacuate all chips under all cutting conditions. The core or web of a drill is the area of the tool along the center axis that has no machined flutes. The diameter and longitudinal shape is what creates the radial stiffness of a drill and enables it to resist deflection.

In this most recent product roundup, MMT continues to offer a variety of innovative as well as tried-and-true technologies to benefit moldmakers.

Rusty tools are another story, so they'll probably need a proper liquid rust remover like Evapo-Rust. We tested four of the leading rust removers that require little scrubbing and are highly effective.

When used for conformal cooling in plastic injection, 3D printing opens a wide range of design freedom. This design freedom enables designers to develop highly-efficient thermal regulation networks. However, this blessing also comes at the expense of not only higher manufacturing cost but also higher design cost as the designer could spend weeks to develop optimal cooling channels. This webinar will explore strategies and tools — including SimForm, a front-end thermal simulation app — to help tool designers and tooling managers maximize the benefits of 3D printing while minimizing manufacturing and design costs. Agenda: 3D printing applied to the plastic injection industry 3D printing pros and cons Tools and methods to facilitate the integration of 3D printing

Drill MillCutter

On June 25-27, 2024, RAPID + TCT returned to the West Coast for the first time in nearly a decade! The three-day event featured the latest in 3D-printing technology from the industry’s leading product and service providers, a full schedule of speakers including a keynote series, and over 125 hours of educational content. The expansive show floor showcased over 400 exhibiting companies’ latest advancements. And next year? It will be even better! Start planning your trip to Detroit, MI to experience North America’s largest additive manufacturing and industrial 3D printing event in 2025!

When plunge roughing a chamber or cavity, it is always best practice to drill the solid diameter holes first at a much faster feed rate, then drill the rest of the material between those first holes.

Drill MillBit

M.A.Ford® TuffCut® GP 3 Flute End Mill 9/64x1/2x2.

Identifying specific areas where CAM software can utilize machine capabilities to benefit the user and maximize milling machine potential.

Plunge roughing uses a cutting tool in an axial direction for material removal, similar to drilling. This process requires a tool that is designed to handle such axial cutting, such as indexable drills and milling tools, two common tool types that each have their own benefits and limitations.

Because of the lack of crushing, refining, and flattening of the salt crystals, fine salt has a powdery, pourable consistency, whereas coarse salt has a rough, ...

Proper cooling is crucial in molding, yet often overlooked. Discover proper cooling methods to prevent defects and improve efficiency.

Carbide drill bits are made from tungsten carbide, a compound of carbon and tungsten. This material provides faster cutting speed, more durability, and ...

For maximum drilling performance, other drills are designed with two separate, small coolant channels that are drilled through when the tool is in a rough-machined state during manufacture. The tool body is then heated and twisted to match the helix angle of the fluting, creating a completely solid core of the tool and two independent helical coolant channels that take the coolant flow directly to the cutting edge.

In ISO 9001 quality management systems, the Management Representative (MR) plays a crucial role. While the 2015 version of ISO 9001 no longer mandates this position, having a trusted management member serve as an MR remains vital for streamlining operations and maintaining quality standards.

Chip formation is always a critical aspect of a machining operation. The goal is to achieve a consistent chip shape and size, easing chip evacuation. Since complex chipbreaking topographies can be pressed into an insert, it is relatively easy to get a good drill to form a consistent chip when running with the proper insert grade, geometry, coating, speed and feed. Using the tool in a plunging operation adds an interruption to the cut, which aids in chipbreaking, but it also requires an insert edge that can handle the added shock. It is typically advisable to use an insert topography with a large land width and hone for a strong edge, and a suitably strong substrate grade that will not fracture under impact with the material.

Mix a 1:1 solution of laundry detergent and water in a bowl, and allow your drill bits to soak for about 10 minutes. Remove your tools and use a plastic brush or toothbrush to clean them off. When done, use a rag to thoroughly dry them and place them back in storage.

Over time your drill bits, router bits, and saw blades, will accumulate dirt and baked on deposits. Dirty cutters lose their effectiveness and cause bits to heat up more, which diminishes their lifespan. Instead of cleaning your bits and blades with toxic chemicals that require gloves and proper ventilation, use your liquid laundry detergent for surprising results.

After attending IMTS, it's clear that the integration of advanced technologies is ready to enhance precision, efficiency and automation in mold manufacturing processes. It’s a massive event, so here’s a glimpse of what the MMT team experienced firsthand.

Strategic operation planning and cutting tool system optimization can make plunge roughing a productive, stable choice for high-volume material removal.

Essential tools and resources to support mold builders in making critical strategic decisions about doing business in Mexico.

A water-based, eco-friendly plastic mold cleaning system helps Rankine-Hinman Manufacturing restore flow rates and avoid big-ticket failures on complex and costly molds.

Alba Enterprises created a mold base to match the needs and pacing of product iteration using mold tooling made via additive manufacturing.

Discover how to enhance your mold design process with the right CAD/CAM tool for parting and cavity design. This webinar will explore CAD/CAM capabilities including how hybrid solid/surface modeling can streamline workflow and improve accuracy. Learn how to confidently tackle parting, runoff, and shutoff, ensuring precision and efficiency in your designs. Agenda: Part analysis QuickSplit techniques Parting and runoff strategies Shutoff solutions

Critical Cleaning Hands-on Workshop Do it; learn it! The one-day workshop teaches how cleaning and cleanliness testing work. By participating in hands-on exercises of techniques for cleaning and cleanliness verification, attendees gain the understanding and knowledge to make practical, effective, and sustainable manufacturing decisions. While exercises are supplemented by demonstrations and tutorials, the workshop is not death by PowerPoint! Topics include aqueous, solvent, and “non-chemical” cleaning, including cleaning chemicals and cleaning processes (spray, ultrasonics, cyclic nucleation, in-line, batch). Most manufactured product and product contact surfaces require cleaning during (and sometimes after) manufacture and assembly. Examples of areas where effective cleaning is essential include: metal fabrication, product assembly, optics, electronics, microelectronics, wafer fab, medical devices, aerospace/aeronautics, military, and additive manufacturing. WHAT DO YOU CALL CLEANING? There are many different terms for cleaning. Cleaning Precision Cleaning Critical Cleaning Safety/Critical Cleaning Surface Prep for Finishing Technical Cleanliness Residue Removal WHO WILL BENEFIT FROM THE WORKSHOP If you or your company fabricates, finishes, maintains or repairs product or product contact surfaces (like reaction vessels), this workshop is time well-spent. If you sell chemicals or cleaning equipment, this workshop will help you better understand and optimize the market for your products. Examples include: Manufacturing Engineers Product Designers Managers Sales and Marketing Managers Facilities Personnel Assemblers, operators Process Technicians Quality Control Personnel Regulatory Affairs Experts (industry, military, and government) Safety/environmental professionals Participants will receive a PDF Certificate of Completion with continuing education credits from Sam Houston State University.

Mill vs drillpress

Alba Enterprises created a mold base to match the needs and pacing of product iteration using mold tooling made via additive manufacturing.

Timothy is a lifelong DIY enthusiast who is fixated on smart home tech, beautiful tools, and wrenching on his FJ62 Land Cruiser. He’s the DIY editor at Popular Mechanics and also the founder of the home improvement site, Charles & Hudson, the Webby-nominated family site, Built by Kids, and Tool Crave. When not working, you’ll find him on his board or bike enjoying the LA weather with his family and friends. Follow him on Instagram and Twitter.

Mill Drill

Intensive workshop teaches the process of mold maintenance to help put an end to the firefighting culture of many toolrooms.

Extrusion's general sessions cover best practices, troubleshooting and processing solutions that can help you run your operation and maximize the utilization of your existing assets—as efficiently as possible. Extrusion professionals from the shop floor to the front office are represented at the Extrusion Conference. You’ll meet the entire global supply chain: manufacturing managers, supervisors, engineers and technicians, as well as engineers and technical managers at OEMs and other firms.

2023525 — Carbon fiber reinforced polymer composites (CFRP) are lightweight and strong materials that are used to manufacture many products that we use in our daily ...

This webinar will provide an overview of new developments in hot runners, controllers, mold components, predesigned molds, process monitoring and mold maintenance equipment. These advancements are designed with the goals of lowering scrap rates, optimizing process temperatures and managing energy consumption. The solutions also aim to support productivity and may contribute to extending the operational lifespan of tooling equipment. Agenda: Innovative undercut and thread-forming components Predesign mold bases and plate control Melt delivery and control solutions Process monitoring and maintenance

Join this webinar where Hexagon will explore how state-of-the-art CAD/CAM technology can drive your business forward. Learn how to optimize tool paths, enhance design accuracy and reduce lead times with advanced simulation. Discover the power of automation and real-time data for continuous improvement. Tailored for mold and die manufacturers, this session offers actionable insights to boost productivity and quality. Don’t miss this opportunity to gain a competitive edge in progressive die manufacturing. Agenda: Key challenges in progressive die manufacturing Optimizing tool paths Enhancing mold and die design accuracy Reducing lead times with simulation Automating processes for greater efficiency Leveraging real-time data for continuous improvement

Chip evacuation is the final key characteristic of a solid drill that can be used for plunging. Most drills have a flute configuration that is sufficient for solid-diameter drilling, with material completely around the circumference of the tool. However, when plunge milling, the drill will commonly no longer be fully engaged based on diameter, and there will be an open area along the circumference of the tool into which chips will fall instead of falling axially along the drill flutes. Damage will result if the chips that fall through the open area get caught between the tool body and the workpiece. Special care should be taken to ensure the chips are being evacuated cleanly when using a new plunging drill in a difficult application for the first time.

Here are techniques commonly used to combat chatter and guidelines to establish a foundation for optimizing the moldmaking process.

Some high-feed mills can achieve a metal removal rate of more than 50 cubic ipm, but very few machines can handle such speeds accurately without problems. Success with high-feed milling is also very dependent upon the tool path as well as minimal non-cutting time in order to reduce cycle time. Plunge roughing, on the other hand, is a much more dedicated solution with fewer variables. Its success is impacted only by speed, feed rate and stepover, whereas a traditional milling operation relies on the same, plus program tool path, dynamic feed rates around radii, tool engagement percentage and toolholder radial stiffness.

Tool Design Elements Since both indexable drills and most milling tools can be used for these plunge roughing operations, let’s examine the unique aspects of each.

titanium, cobalt bits are usually the best drill bits for stainless steel. Carbide-tipped drill bits stay very sharp over long periods of use and are used ...

This illustration shows two possible stepover patterns for plunge milling, with the respective maximum stepover width of cut based on the insert land width.

A discussion with AMT’s Bill Herman during ShopTalk on the big stage at IMTS 2024 highlights moldmaking's unique blend of craft and technology that is driving innovation while its community tackles key challenges.

From an insert perspective, the cutting edge geometry and position have a huge impact on cutting performance and stability of the drill itself. Since inserts are pressed, they can be given very complex topography that is not possible in grinding solid tools. This, along with a pocket manufacturing method, allows tight control of mounting and position angles, such as the gamma angle that defines the radial angle in relationship to the center line of the drill axis. The angle at which the insert sits, the cutting edge design and the contact point of the insert on the material all determine how forces act on the drill.

PTXPO 2025 is a comprehensive showcase of cutting-edge technologies and innovations within the plastics molding industry. Join fellow molders, moldmakers, brand owners, OEMs and their full suite of suppliers in Rosemont, IL for three days of non-stop networking, education and business development opportunities.

Intralox's integration of the Alpha Laser ALFlak has significantly improved their tool room efficiency when it comes to difficult welds and urgent repairs.

Need help in finding the right product · Home · Indexable Cutting Tools · Indexable Inserts · Turning & Profiling Inserts · Turning Inserts ...

Discover how to enhance your mold design process with CAD/CAM software specifically tailored for the moldmaking industry. In part two of this webinar series, Cimatron will demonstrate how to intelligently design mold components, such as slides and lifters, using powerful CAD/CAM tools to accelerate the design process. Additionally, it will cover how to avoid errors and ensure design accuracy for ejector pins by checking clearance distances, calculating cutoff heights correctly, and thoroughly documenting all ejector components. Agenda: Slides Lifters Inserts Ejection pins and charts

Sustainable, productivity-boosting innovations for moldmakers, including stress relief, traceability and cooling solutions.

Join MoldMaking Technology Editorial Director Christina Fuges as she discovers the benefits of eLearning, including promoting sustainability in moldmaking by reducing travel, minimizing waste and enhancing global workforce accessibility.

The Manufacturing Technology Series East, featuring EASTEC in West Springfield, Massachusetts — is at the epicenter of a region that is a traditional manufacturing powerhouse. Historically, more than 700 companies have connected at this event to network, learn from industry experts and explore the latest manufacturing technologies.

High-feed milling can significantly outweigh potential reliability challenges. Consider these six strategies in order to make high-feed milling successful for your business.

Turning Insert|Search from Order Number ... :Inventory maintained in Japan. Return to TOP. Technical Information · Metallic Materials Cross Reference List ...

As indexable drill design has improved over time, they have became better candidates for plunge roughing operations. Solid high speed steel (HSS) and carbide drills are typically not good choices for plunge roughing, as their steep point angles can push the tool off center if less than 60 percent of the cutter diameter is engaged in the part material. Also, solid drills do not handle the shock associated with plunging very well. Carbide, for example, can easily break if exposed to high shock loads.

These humble but essential fasteners used in injection molds are known by various names and used for a number of purposes.

The Society of Plastics Engineers’ Mold Technologies division is accepting applications for a $3,000 student scholarship honoring Joseph Prischak and a $5,000 educational grant program.

Consider this example to prove the effectiveness of plunge roughing versus high-feed milling: A section of material equivalent to 325 cubic inches needs to be roughed out from a P20-steel block. The two tool choices are a 2-inch-diameter high-feed mill and a 2-inch-diameter indexable drill. The initial cutting parameters of the high-feed mill, when taking a full-width pass, are 825 surface feet per minute (sfm), 0.0315 inch per tooth (ipt), four cutting edges and a depth of cut of 0.078 inch. This equates to 1,570 rotations per minute (rpm) and 198 inches per minute (ipm) with a material removal rate of 30.9 cubic ipm. So the machining time theoretically will be 10.5 minutes, excluding any non-cutting time. The initial drill cutting parameters are 700 sfm with a feed rate of 0.008 inch per revolution (ipr). This equates to 1,337 rpm at 10.7 ipm and yields a material removal rate of 33.6 cubic ipm for a theoretical time of 9.7 minutes.

High-feed mills can work very well for plunging applications, as the entry angle of the insert is usually 10 degrees or less. This places most of the forces axially towards the spindle for very high stability. The small entering angle also creates a very wide cutting land, so a relatively large stepover can be used, increasing productivity. Using high-feed mills for plunge roughing also works very well in profile roughing applications, such as along a wall without a lot of material or a very deep or tall part wall, which require a long length-to-diameter ratio for side milling.

Dec 19, 2017 — The lathe manger has asked me to see if we can program a new thread if we cut back the tube to fresh metal. This is something I have yet to try in MC.

Mill vs drillfor metal

M.A.Ford® TuffCut® XR-AL 3 Flute Roughing End Mill for Aluminum 3/8x1x2-1/2x.020R Gem+ Weldon.

The high-strength steel body of indexable drills, coupled with a complex cutting geometry on the insert, increases the abuse these tools generally can handle. However, not all tools are created equal. Some key design elements for a stable process are drill stability, chip formation and chip evacuation.

Diamond compounds, with their varied grades, colors and base options, provide a comprehensive solution for mold builders in need of precise and superior polishing across diverse materials and applications.

However, there are benefits to using an indexable mill in plunge roughing. For example, it often has a stronger body than a drill, since these tools are much shorter and typically have very small flutes, so radial forces are not as much of an issue. Also, an indexable drill typically only has one effective cutting edge, as the inboard and outboard inserts are not cutting the same path. A mill of similar size will have more effective cutting edges, since all cutting edges are cutting the same path, and this can greatly increase the feed rate per minute, bringing the material removal rate (MRR) closer to that of a drill, even though less material is being removed per pass. In some cases, the MRR may even be greater.

MoldMaking Technology addresses the complete lifecycle of the manufacture and maintenance of a mold—from design to first shot—by providing solutions and strategies to moldmaking professionals charged with designing, building and repairing molds. About Us

Endmill vs drillbit

Plunge roughing can be a great alternative to traditional rough machining strategies. It stands out in setups with poor stability in which cutting with axial tool pressure is a much better option. With good operation planning and some time spent optimizing the cutting tools in the system, plunging can be the most productive and stable choice for high-volume material removal.

Milling machine

What exactly does a hot runner do? If you’ve been in the injection molding industry for any length of time, you might think the answer is obvious, but it is not.

These images show examples of very difficult drilling conditions for an indexable drill. The design of this particular drill provides excellent stability, chip formation, chip evacuation and long service life, making it well-suited for plunge roughing. Images courtesy of Komet of America.

Balanced forces around the drilling axis will create a very stable and smooth drilling operation. When the drill is used as a plunging tool, its diameter is not always fully engaged, which makes this process much more difficult as the force vectors change relative to the tool axis. Most high-performance indexable drills are designed with these issues in mind. The better balanced the drill forces are, even under poor conditions, the more aggressive and difficult applications the drill can perform, including, for example, drilling through a step, uneven entry or exit, drilling on a point, or even drilling through a welded seam.

ReelView Fishing faced an electronics obstacle in the development of its new technology for underwater video. Additive manufacturing for moldmaking enabled the speed necessary to iterate to a solution.

Titan USA, Inc is a 105,000 sq feet automotive parts manufacturer providing metals stampings and welded assemblies to the automotive sector located in Warren ...

Benefits Breakdown A drawback of plunge roughing is very limited profile control, since using the tool in a plunging tool path will always leave a radius-shaped scallop on the part equal to the tool radius. So, unlike a traditional milling tool path that can be programmed to create any shape, plunge-milling tool paths cannot create smooth contours. Drilling, by nature, typically offers the highest material-removal rate of all machining operations, so using a drilling operation will create a productive operation with a flexible profile path.

The mathematics of this example prove that plunge roughing with the indexable drill is favorable in terms of time, however there are many other factors that should also be considered to ensure this is the most economical solution for a particular job, including tool path, material shape, machine power and speed.

Plunging with indexable mills works best when cutting through to an open pocket or along a wall of a part with no floor. Since indexable mills do not cut all the way to center of the tool, it is critical to make sure that the steel body does not contact any material left on the floor of the component by a previous stepover. Sometimes it is necessary to reduce the depth of each stroke when taking multiple steps, so the tool does not contact the floor, which would require material to be removed in another semi-roughing operation.

Why does the gate appear repeatedly for me? If the gate continues to show up on premium content after you’ve already provided your information, it could be for one of these reasons:

Sustainable, productivity-boosting innovations for moldmakers, including stress relief, traceability and cooling solutions.

This comparison shows the strength zone of straight-shank (top), flanged (middle) and shank (bottom) tools. While a flanged tool is an improvement over typical straight-shank tools without a flange, it still does not have the same strength zone as a modular drill that has a larger flange diameter and is preloaded to the flange face by the locking screw. This creates some stress in the tool that greatly increases the radial stiffness, making the steel body resistant to bending during plunge roughing or difficult drilling.

Continued training helps moldmakers make tooling decisions and properly use the latest cutting tool to efficiently machine high-quality molds.

Endmill vsfacemill

A main difference among drills is coolant channel design. A common way to create a coolant channel is to drill one main feed hole through the center of the tool, then two connecting passages to each insert. This is easy and relatively inexpensive to manufacture, however it does reduce the solid material area in the core. Under light drilling conditions, this may not be an issue, but pushing a tool to its physical limits will be noticeable, especially if it is not fully engaged, which adds a radial load component to the tool itself.

Whether using a drill or milling tool, the toolholder is just as important. Tool stability is critical to eliminate deflection that can cause tool failure during plunging. Milling tools have a larger body with a large core that is very stable and can be mounted solidly to a spindle adapter. A good rule of thumb is to avoid using a tool that is larger than the diameter of the spindle taper at the spindle nose. This ensures that the forces remain toward the spindle centerline. For example, using a large 6-inch-diameter tool to plunge a component with a CAT40 spindle would create excessive loads too far from the spindle centerline and would most likely deflect, chatter and break inserts.

Indexable milling tools can also be used in plunge roughing operations, but they have a more limited stepover equal to their insert land width. This is the length of insert edge that can be used for cutting in that orientation without damage or wear to the second side of the insert that could be used if indexed. If the stepover of the tool is greater than the insert land width, it is possible that the steel body of the tool will also contact the material, causing tool failure and part damage. In turn, the amount of material that can be removed per stroke with indexable milling tools is limited compared to drills of a similar size.

Mark the calendar for AMBA Conference 2025, "Breakthrough Innovation," May 7-9, 2025, Grand Rapids, MI. During this industry event, attendees will meet with peers to discuss best practices in business, employee management, technology and more.

Identifying specific areas where CAM software can utilize machine capabilities to benefit the user and maximize milling machine potential.

Report analyzes moldmaking trends, pricing, labor shortages, capital costs, competitiveness strategies and construction spending challenges.

Since indexable drills have flutes that continue to a certain length up the tool, they are a little weaker by design. This is where the tool connection becomes important. A flange on the tool that will act as a positive stop on the holder is a requirement. However, on traditional straight-shanked tools with a flange, that feature only stops axial movement and does not add any significant radial stiffness. In modular connections, the connection diameter is much larger, and there is a significant increase in radial stiffness even in long projections due to the unique clamping style of the modular connection.

The need for data to track information and the history of the mold-building process is ever-increasing, and mold component solutions can help.

While the transition from traditional methods to this innovative approach may present initial challenges, the benefits far outweigh the learning curve. Through the NextMold and partner network, Forward AM provides comprehensive support at every stage of the integration process. This ensures a smooth adoption of the technology into company’s operations, including seamless collaboration with molding companies. Forward AM’s commitment is to facilitate this technological transformation, enabling your business to leverage the full potential of 3D-printed mold inserts. Agenda: Molding with 3D-printed inserts Ultrasim3D Next Mold: Forward AM offering Successful adaption: integration at Beaumont Technologies

To continue enjoying the articles, videos and podcasts from the MMT editorial team, please key in your name and email address, as well as your company and title info. Doing so unlocks MMT’s premium web content on this device.

Smart sensors and sophisticated process and measurement data management are driving intelligent moldmaking to new heights.