"It's simply not practical to say that for a given operation and workpiece material, this or that style and grade of insert is best for hard turning," says Mr. McCarthy. "So many other factors have to be considered. But understanding those factors will help many shops recognize opportunities for hard turning that they might otherwise have overlooked.

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CBN inserts forhard turning

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So why isn't everybody doing it? Obviously, hard turning is not an option in every case, but not every application for hard turning is being taken advantage of. One reason is that some potential users are under the impression that they'll have to make a big investment in new tool-holders and/or new fixtures, not to mention the higher cost of those CBN inserts. The other reason is that they are afraid their existing machines and setups aren't up to the higher speeds and resulting higher cutting forces that are involved in hard turning.

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Table I (below) gives some representative parameters proven for hard turning. As these figures show, the essence of hard turning is high sfm and low depth of cut.

For example, he cites one plant that adopted hard turning to finish the bore ID on a pinion gear of 5120 steel (62 Rc). In this case, 11 grinders were replaced with five lathes. Many shops find that reduced coolant costs from dry cutting more than offset the higher price of CBN inserts, Mr. McCarthy says.

In an occasional instance, a shop that has been under pressure to get a good return on the investment represented by a high-ticket turning center may find that heavy use has produced more wear than might be expected, whereas a well-maintained manual lathe subjected to less demanding duty may actually turn out to be a candidate for hard turning. The lesson here, Mr. McCarthy stresses, is that the best piece of equipment for taking advantage of the hard turning process is an open mind.

The point is, in most cases, where toolholders and chucks are in good repair and are properly used, they can also be used for hard turning.

Verisurf’s Machine Tool Probing (MTP) suite is an in-process automated inspection solution for CNC machine tools, offering inspection and reporting capabilities.

Turning insertfor hardened steel

Hard turning does call for a change in thinking about the shape and style of inserts that are applicable but not a radical shift in tooling concepts. That common sense is a principle guiding factor becomes clear in some general guidelines about hard-turning Mr. McCarthy offers.

This page offers two Free Online Speeds and Feeds Calculators. Use Cutting Speeds And Feeds Calculator with simple shop formulas and .Most CNC lathes have constant surface speed to counteract that natural decrease, which speeds up the spindle as the tool plunges in. Photo of a milling cutter during a cutting operation. .

Regarding toolholders, Mr. McCarthy has this advice: Standard toolholders work fine to clamp the insert for single-point cutting. The toolholder clamping components, however, must be in good condition. Carefully examine the top clamps, cam lock pins, and screws. If they are worn, replace them.

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To improve the process and reduce high insert usage, the shop owner went to a CBN-tipped, Fansteel VR/Wesson DNGA 432 insert. This insert had a 0.006-inch by 20-degree K-land. A cutting speed of 600 sfm, at 0.02 inch depth of cut, was recommended, with no coolant. "The owner was a little nervous because the speeds were much higher than he was accustomed to," Mr. McCarthy recalls, "but once he let the machine and tool do its work, the results were reassuring."

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The tool crib is the backbone of any machine shop — without the right tools, nothing moves forward. While most ERP systems overlook the tool crib, ProShop integrates it seamlessly with CNC programming, job planning, scheduling and more. Join this webinar for an exclusive look at how Roush Yates Manufacturing Solutions leverages ProShop to document tool requirements, sync tool demand from CAM software and efficiently manage the tool crib and work instructions. Discover how ProShop transforms the tooling workflow to maximize efficiency and precision.

For most material that you will be cutting on a CNC router you will typically set the RPM between 12000 and 24000, and adjust your feed rate to obtain the required results. The speeds and feeds chosen can be affected by the power of the spindle being used.

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The one aspect of hard turning that may take some getting used to is the high surface speed involved. Nonetheless, these high speeds are essential. "If you fall below what is recommended, the insert will wear quickly and fail," warns Mr. McCarthy. "Hard turning has certain running parameters that must be followed to achieve success," he says, pointing again to Table I, "but the results are worthwhile."

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.

ModuleWorks and Toolpath announce a technology partnership that intends to utilize intelligent cloud-based manufacturing solutions for machining estimation and CAM automation.

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Plus, he points out that grinding machines may be two or three times the purchase price of a lathe. In numerous companies where hard turning has replaced conventional grinding, these plants are averaging one-third the machine tool investment. Further, cycle times and setups are generally much shorter on lathes, he notes.

Mr. McCarthy stresses that shops should not be afraid to experiment once they get a feel for hard turning. Similarly, they should not expect to find definitive answers, from outside sources, about what hard turning parameters are best for their application. Nobody's got an infallible cookbook to refer to that takes in all of the variables that come into play in every shop. Shops should expect to do some tweaking, he says.

The Best Online Speeds and feeds calculator. For Milling, Turning, Drilling, Grooving, and Parting off. Results: Cutting conditions and Grades This page offers two Free Online Speeds and Feeds Calculators. Use Cutting Speeds And Feeds Calculator with simple shop formulas and access a full-featured, industry-leading calculator (free for a limited time).Most CNC lathes have constant surface speed to counteract that natural decrease, which speeds up the spindle as the tool plunges in. Photo of a milling cutter during a cutting operation. Arrows show the vectors of various velocities collectively known as speeds and feeds. In CNC machining and manufacturing, cutting speed is critical to the operation result and has the greatest impact on tool life. Cutting speed is the spindle speed, while it can be regarded as the speed of tool or the work moves at the point of cut.

Determining whether to use high-density fixtures or to simplify workholding requires a deeper look into the details of your parts and processes.

The greatest advantage to hard turning, however, is that it eliminates a grinding operation to finish the part. Therein lies the payoff that makes hard turning such an attractive alternative to many machine shops.

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Soraluce’s wide range of machine heads and the ability to have multiple heads on a single machine (with automatic changing stations) provides flexibility and reduced setups for large-format machining.

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When it comes to utilizing the spindle’s power, there is a lot of headroom at the upper limits, provided it’s in short bursts. Be mindful of your time at these loads so you don’t stall out.

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"How the hard-turning process works is simple," says Mr. McCarthy. "If you are finish-turning a shaft of 60 Rc hardness at 400 sfm with an 0.008-inch depth of cut, the material being removed will have an Rc hardness approximately in the 30s range. That's because all of the heat generated at this cutting speed is concentrated where the chip is being formed, causing it to anneal ahead of the cutting action, while the parent material remains unaffected. In fact, this annealing effect is even more pronounced if the speed is increased, so the Rc of the chips drops even further. Hence, the faster the speed, the more parts per tool. We suggest starting at the low end of the recommended sfm and work up to the optimum speed."

Hard turning insertfor steel

Adding pallet systems brought Mach Machine success and additional productivity. The shop has since furthered its automation goals while adding new capabilities.

Bob McCarthy, the CBN/PCD Product Manager at Fansteel VR/Wesson, a supplier of cutting tool inserts and toolholders, says that both of these concerns need to be re-examined. In a great number of applications, his experience shows, existing toolholders are more than adequate for hard turning. For example, if a shop is tooled up for 80-degree diamond inserts in carbide, he encourages them to run CBN-tipped inserts of the same shape in the same toolholders for hard turning--at much higher cutting speed (surface feet per minute or sfm), of course.

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.

How can shops can make informed decisions using data-driven feedback to improve shopfloor efficiency and profitability? And how will these technologies differ between high- and low-volume production?

Likewise, Mr. McCarthy believes that many shops are too quick to rule out hard turning because they do not have the latest turning equipment. What is important, he says, is the condition of the machine, not necessarily its age. For hard turning, a lathe must be rigid, have sufficient spindle rpm, and adequate horsepower. A well-maintained CNC (computer numerical control) lathe is a likely candidate for hard turning.

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In CNC machining and manufacturing, cutting speed is critical to the operation result and has the greatest impact on tool life. Cutting speed is the spindle speed, while it can be regarded as the speed of tool or the work . This guide explores an in-depth comparison of feed rate and cutting speed in CNC machines. Continue reading to learn their key differences and their critical roles in optimizing your CNC process to achieve optimal results! If you are about to cut or mill anything with your CNC machine, understanding feed rates and RPM speeds is vital. They will significantly affect your tool life, surface finish, and machining time – so this is a crucial calculation to get under your belt.

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Likewise, to protect the cutting edge from chipping, a T-land or K-land is a must on hard-turning inserts. An edge hone also helps the edge resist chipping. Standard K-lands appropriate for hard turning are from 10 to 25 degrees by 0.004 to 0.010 inch wide, depending on the material and depth of cut.

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Speed parameters of a CNC machine consist of two types of speeds: cutting speed and spindle speed. Cutting speed is the relative speed between the workpiece and the cutting tool. It can be defined as the speed at which a particular point of workpiece passes through the cutting edge.Free CNC Speed and Feed Calculator allows CNC Machinists and CAD/CAM Programmers to calculate milling and drilling speeds and feeds for a wide variety of materials, and tools types.

The machine was able to make 40 parts with one CBN insert, holding a 0.0002-inch tolerance on all 40 parts. Cycle time was reduced to 1.5 minutes, allowing what used to take 20 hours to be completed in one shift. Surface finish was superior, too, making the finish grinding operation unnecessary. Cutting dry also eliminated costs associated with handling and disposing of coolant.

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No, says Mr. McCarthy. Compared to the carbide inserts, CBN inserts are considerably more expensive (from four to five times more costly per insert), but one CBN tool produces many, many parts. But that isn't the point at all, he says. The cost of tooling is trivial when one looks at savings from eliminating a finish grinding operation.

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.

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At these speeds, heat goes out with the chip and not into the tool or the workpiece. Cutting dry--without coolant--is one benefit. Improved surface finish and reduced machining time are other benefits.

As a general rule, if the lathe generates vibration, chatter, and poor surface finishes with carbide tools, it would not be a good candidate for hard turning.

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The workpieces were 2 inches in diameter, 1 inch long. The part was faced, then a shoulder was turned, followed by turning of the OD. Each cut removed 0.02 inch, with the carbide inserts. Cycle time totaled 3.5 minutes. The parts were subsequently finish ground to complete.

To make the transition to hard turning, you'll need to switch from carbide to CBN inserts, but that is easier (and more economical) than you might think. It's making the jump to much higher surface speeds that might scare you off. It needn't. Here's why.

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Pacon Mfg, Inc. has not rested on its laurels as the 2020 Top Shop Honoree for Shopfloor Practices and Performance. In the years since, it has refined its processes to continue excelling in a volatile market.

This guide explores an in-depth comparison of feed rate and cutting speed in CNC machines. Continue reading to learn their key differences and their critical roles in optimizing your CNC process to achieve optimal results! CNC cutting speed and feed rate are the two most important variables, they directly affect the production speed, precision, chip evacuation, surface finish, and tool life. Therefore, considering their optimizations is essential for any CNC machining project.

The "secret" to successful hard turning is high surface speed. Applications typically involve tripling or quadrupling the surface speed used for carbide inserts when CBN inserts are substituted. CBN (also called PCBN, polycrystalline cubic boron nitride) is a man-made material second only to diamond in hardness.

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CNC lathes are recommended for hard turning, but manual lathes can be effectively utilized as well. A manual lathe must be in excellent condition and have very little play in the cross-slide toolpost and tailstock. Mr. McCarthy notes that shop managers should be careful not to assume that older equipment will be inadequate or that newer equipment will automatically measure up.

How can shops can make informed decisions using data-driven feedback to improve shopfloor efficiency and profitability? And how will these technologies differ between high- and low-volume production?

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Ditto for the chuck or fixture that will hold the workpiece for hard turning. Be sure it is in good condition. Check jaws for wear. A solid grip on the workpiece is essential because "vibration is a CBN tool's worst enemy," as Mr. McCarthy reiterates.

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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.

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cnc machine cut speeds|material cutting speed chart Versatile in production with wood and many other materials, these CNC machines are one of the best CNC routers you’ll find on the market. From 3-axis, 4-axis, to 5-axis CNC routers, these .

Many plants that manufacture hardened steel bearings, gears and axle shafts use this process. According to Mr. McCarthy, they can consistently hold dimensional tolerances to ±0.0004 inch or better over long production runs and achieve excellent surface finishes.

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Even before inspection, Datanomix and Caron Engineering’s TMAC AI can extrapolate part quality from cut information. This information also helps shops push their tool life to its limits.

"Hard turning with CBN inserts can streamline the manufacturing process, increase productivity, provide consistent quality and lower rejection rates," he says.

Typical materials that are hard-turned are 5120 steel (62 Rc), 1050 steel (62 Rc), 9310 (60 Rc) and 4320 steel (60-62 Rc).

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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 example, in most applications, hard-turning inserts should be negative geometries. Negative rake angles give good support to the cutting edge, where it is needed most because higher speeds and relatively light depths of cut concentrate forces there. (However, in certain boring operations, positive geometries are best because they are available in different inscribed-circle sizes, such as 0.125, 0.156 and 0.250 inch.)

How can shops can make informed decisions using data-driven feedback to improve shopfloor efficiency and profitability? And how will these technologies differ between high- and low-volume production?

The new space includes a showroom, office spaces and an auditorium that will enhance its work with its technical partners.

Custom workholding enabled Resolve Surgical Technologies to place all sizes of one trauma part onto a single machine — and cut days from the setup times.

Each year Products Finishing partners with thousands of finishing operations in the U.S. to celebrate National Surface Finishing Day (NSFD) on the first Wednesday in March. NSFD is designed to celebrate and showcase the industry to trade schools, businesses, officials and media, as well as to celebrate employees and staff. The overarching goal of NSFD is to bring further awareness to the important roles plating and coating facilities play in their communities. Facilities are encouraged to host events and work with local media to build awareness about the contributions made by the surface finishing industry. For a helpful guide to reaching out to media outlets, download the NSFD toolkit here. How can you celebrate? Share your company’s story Hold an open house where the public can check out your facility –— either in person or virtual Offer student shop tours to local trade schools Invite local elected officials to visit and get to know your staff Celebrate your employees Share news about what you’re doing on social media and use the hashtag #NationalSurfaceFinishingDay or #NSFD

In CNC machining and manufacturing, cutting speed is critical to the operation result and has the greatest impact on tool life. Cutting speed is the spindle speed, while it can be regarded as the speed of tool or the work moves at the point of cut. This guide explores an in-depth comparison of feed rate and cutting speed in CNC machines. Continue reading to learn their key differences and their critical roles in optimizing your CNC process to achieve optimal results! CNC cutting speed and feed rate are the two most important variables, they directly affect the production speed, precision, chip evacuation, surface finish, and tool life. Therefore, considering their optimizations is essential for any CNC machining project.

Adding pallet systems brought Mach Machine success and additional productivity. The shop has since furthered its automation goals while adding new capabilities.

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.

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.

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?

The first question a shop needs to address regarding hard turning focuses on the machine tool. The issue, summarizes Mr. McCarthy, is rigidity. Hard turning requires a rigid machine with a rigid toolholder system. Otherwise, the cutting tools will wear quickly and be prone to chipping. Surface finishes will be poor and dimensional accuracy will be questionable. "Vibration is a CBN tool's worst enemy," he says.

Sandvik Coromant’s CoroCut 2 with -RF geometry is designed for secure and high-precision profiling, eliminating the trade-off between chip control and optimized surface finish.

Determining whether to use high-density fixtures or to simplify workholding requires a deeper look into the details of your parts and processes.

Turninghardened steel

Determining whether to use high-density fixtures or to simplify workholding requires a deeper look into the details of your parts and processes.

Hard turning is a process in which hardened steels (above 45 Rc) are finish turned. In other words, a lathe or turning center provides the last operation bringing the workpiece to final shape and surface condition. Hard turned parts do not need to be finish ground.

As the demand for faster production cycles continues to grow, the ability to produce high-quality parts quickly and efficiently has become increasingly important. High-speed 3D printing has emerged as a key solution to reduce lead times and increase productivity across industries. However, like any advanced technology, it comes with its own set of challenges. In this webinar, Forward AM will explore both the opportunities and hurdles of adopting high-speed printing with a particular focus on overcoming those challenges. It’ll start by discussing the fundamentals of high-speed 3D printing and how it differs from conventional 3D printing methods. It’ll then move on to the key factors that influence successful implementation, including the impact of materials, equipment and design considerations. One of the main hurdles in high-speed 3D printing is ensuring the right balance between speed and part quality. Different materials behave differently under high-speed conditions — and not all equipment is optimized for this process. Forward AM will showcase some validated materials and equipment that are proven to perform well under these conditions. In addition, the presenters will look at real-world examples and applications where high-speed 3D printing has been successfully implemented, highlighting the collaboration between designers, engineers and manufacturers. By the end of this webinar, you'll not only have a clearer understanding of high-speed 3D printing with FFF but also the practical steps and considerations needed to make the most of this cutting-edge technology. Agenda:  Introduction The power of high-speed printing Know the process The practical side

Not only can Gelsight’s tactile sensor detect and evaluate defects, but it can also measure part features, surface roughness and even contamination.

"The biggest hurdle isn't always working out the technical issues," he observes, "it's often the psychological factor. Some shops hesitate to give hard turning a try because they are unaccustomed to the surface speeds it calls for. Today we know enough about hard turning to determine when and how to do it safely--and effectively," he points out.

The PSZ Turn System offers products for front-turning, grooving, thread-cutting and back-turning applications. Additionally, the MEFF Chipbreaker enables excellent chip control, low cutting force and good surface finish at a range of depth of cuts.

If you are about to cut or mill anything with your CNC machine, understanding feed rates and RPM speeds is vital. They will significantly affect your tool life, surface finish, and machining time – so this is a crucial calculation to get under your belt. Speed parameters of a CNC machine consist of two types of speeds: cutting speed and spindle speed. Cutting speed is the relative speed between the workpiece and the cutting tool. It can be defined as the speed at which a particular point of workpiece passes through the cutting edge.Free CNC Speed and Feed Calculator allows CNC Machinists and CAD/CAM Programmers to calculate milling and drilling speeds and feeds for a wide variety of materials, and tools types.

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

The Best Online Speeds and feeds calculator. For Milling, Turning, Drilling, Grooving, and Parting off. Results: Cutting conditions and Grades This page offers two Free Online Speeds and Feeds Calculators. Use Cutting Speeds And Feeds Calculator with simple shop formulas and access a full-featured, industry-leading calculator (free for a limited time).Most CNC lathes have constant surface speed to counteract that natural decrease, which speeds up the spindle as the tool plunges in. Photo of a milling cutter during a cutting operation. Arrows show the vectors of various velocities collectively known as speeds and feeds.

Pacon Mfg, Inc. has not rested on its laurels as the 2020 Top Shop Honoree for Shopfloor Practices and Performance. In the years since, it has refined its processes to continue excelling in a volatile market.

Mr. McCarthy points out another oddity about hard turning with CBN that sometimes defies expectations. Generally, the grades used for hard turning inserts are those having roughly 50 percent CBN content, depending on the manufacturer. Grades with a higher content of CBN, on the other hand, are used for conventional turning of softer materials such as powdered metal, gray irons, and certain super alloys.

Commonly used inserts for hard turning are CNGA, DNGA, VNGA, CNMP and TNG styles. Positive inserts for hard turning are CCMT, CPGM, and DCMT.

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.

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

Mr. McCarthy recalls one shop owner who hesitated initially when confronted with the speeds hard turning calls for. The shop was cutting 45 Rc steel with carbide inserts on a three-year old CNC lathe. To produce just one part, the shop was using two carbide inserts, indexing each one time (four cutting points altogether.)

Moving from an aging set of five-axis mills to more advanced machines enabled Hendrick Motorsports to dramatically improve its engine production.

Decker Machine Works recently adopted Rego-Fix’s reCool through-coolant system for ER collets, reducing the cycle times on a nickel alloy job by 70%.

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

OnLogic is partnering with AI development and implementation specialists to help companies use AI-powered solutions, aiming to drive real business value.

Determining the shape of a workpiece is required in many manufacturing processes. Keep in mind these important points to ensure that you master the process.

Speed parameters of a CNC machine consist of two types of speeds: cutting speed and spindle speed. Cutting speed is the relative speed between the workpiece and the cutting tool. It can be defined as the speed at .Free CNC Speed and Feed Calculator allows CNC Machinists and CAD/CAM Programmers to calculate milling and drilling speeds and feeds for a wide variety of materials, and tools types.The Best Online Speeds and feeds calculator. For Milling, Turning, Drilling, Grooving, and Parting off. Results: Cutting conditions and Grades

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.

Coordinate systems tell a CNC machine where to position the cutting tool during the program’s execution for any purpose that requires the cutting tool to move.