Precision Carbide End-mills - end mill bit

2024-11-24 05:15:53

Composite machiningprocess

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

Standard metalworking equipment can be used to perform milling, turning, grinding and other operations on abrasive composite materials. The key is to match the process variables to the material.

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

A simple answer to beveling tube ends is this router-like machine that uses a high-rpm air motor and carbide burr. Beveling can be performed in one-fifth the time it would take for a lathe to machine the profile.

The best drilling results are obtained using diamond-tipped tools with polished flutes operating at (not surprisingly) high speeds and slow feeds. Over the years, the company has found that thin-web drills with helix angles of 10 to 50 degrees, clearance of 9 to 20 degrees and point angles of 60 to 120 degrees work best to limit chip packing and overheating.

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%.

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

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

The company has determined that virtually any machining operation that can be performed on a metal part can also be performed on a composite part. In addition, the milling, turning, drilling and grinding it carries out are done using traditional metalworking machines and tools that were not necessarily designed with composites in mind. As with machining any type of material, the key is matching the process to the part by applying cutting techniques and tooling best suited for composites. It’s really no different than adapting one’s machining approach when switching from an aluminum part to a steel part.

Differential gaging measures using two devices, which has advantages over standard, comparative measurements using a single sensing head. These include the ability to measure size without regard to position.

The MFG Meeting brings together manufacturing technology industry leaders to address key business challenges and provide actionable solutions. Sessions cover a wide range of topics, including workforce, economics, supply chain, leadership, politics, and more. This unique meeting experience provides unparalleled opportunities to network with executives from companies that make, sell, service, and support MT. These peers and competitors will learn from each other, build long-lasting connections, and share insights that will benefit their business.

Compression-molded parts are more prismatic than tubes. They are made from stacking sheet molding compound in a mold, and then heating and compressing the part into shape. These parts generally require workholding methods common to metal parts of similar geometries.

Find Wood Cutting Machine stock images in HD and millions of royalty-free photos, illustrations, and vectors on Shutterstock. 80319 Wood Cutting Machine ...

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

Standard metalworking equipment can be used to perform milling, turning, grinding and other operations on abrasive composite materials. The key is to match the process variables to the material.

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.

HNT2RK, Haas Notch Carbide Threading Insert, Right-Hand, Size 2, Grade HU25 - Pack of 5 ; Chipbreaker, K – Standard Chip Control ; Thread Type, Partial Profile 60 ...

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.

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

During the last 10 years, Amalga Composites has seen a steady increase in the number of customers requesting that their parts be fully machined; parts that might just require assembly, painting or balancing. Dr. DeLuca and Gregg Piper, the company’s vice president of engineering, offered Modern Machine Shop a glimpse into the type of machining work that’s required for their company’s styles of composite parts. They also clued us in as to some of the methods they’ve found effective for machining such an abrasive material.

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.

Pure water is the most common machining coolant. If a machine will be cutting both composites and metals, a water-soluble fluid with 1 to 2 percent of rust inhibitor is used. It is important to use a water-soluble coolant, because that won’t adversely affect paint bonding as an oil-based fluid would. (The porous surface of a machined composite part has numerous nooks and crannies where coolant oils could hide.) Oil- or solvent-based coolants can also wick along exposed fibers, and they won’t evaporate as pure water does.

CCAI is offering a comprehensive Industrial Finishing Safety Seminar developed by industry experts well-versed in safety for finishing operations. This day-and-a-half seminar focuses on NFPA 33, the Standard for Spray Application Using Flammable or Combustible Materials and will deliver important and critical information on how to safely operate an industrial finishing line. Topics Covered: An introduction to safety Overview and definitions General requirements and electrostatic spray equipment Ventilation Storage handling and distribution Fire protection Operations, maintenance and training Drying and curing Liquid and powder coatings Authority Having Jurisdiction panel discussion Who Should Attend? Manufacturing, staff and environmental engineers (industrial health & safety) Lead painters Maintenance leads and personnel Finishing equipment designers System controls and project engineers Facility managers Finishing industry distributors Date: Tuesday, March 11 and Wednesday, March 12 Time: Tuesday - 9:00 AM - 4:00 PM and Wednesday 8:00 AM - Noon Location: Sames 45001 5 Mile Road Plymouth, MI 48170 Registration Fee: CCAI Members: $599 / Non-Members: $750 Registration Fee Includes: Classroom instruction; lunch on day one; a certificate of completion; and a printed copy of the NFPA 33 Standard for Spray Application Using Flammable or Combustible Materials. Registration: CLICK HERE to register. Space is limited.

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

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

Roll wrapping Composites

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

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

K Kiyomura · 2022 · 7 — In this study, a persistent homology analysis was employed to characterize the topological features of cementite component of pearlite steel.

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.

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.

Composites machining is dusty, messy and hard on tools. But this company accepts these difficulties, and machines the material using standard metalworking processes and equipment.

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.

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?

Sep 20, 1999 — Yamaha, Selmer, Armstrong, and Pearl are all fine flutes. I suggest you contact a reputable dealer and try different flutes. Many dealers will ...

Composite machiningtools

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.

Accurate Performance Machine guarantees ALL of the work done for you in our machine shop. We also have another guarantee, a guarantee that you will be a satisfied customer. We believe in fast, friendly, knowledgeable service and that your trust has to be earned. People have trusted Accurate Performance Machine for over 34 years, and we believe that dollar for dollar you can’t find better quality.

Shops that have never cut thermoset composites—material that is approximately one-fifth the density of steel—might not think it would be very tough. The folks at Amalga Composites in West Allis, Wisconsin, have seen shops with similar attitudes give it a shot. Many times, though, a shop’s first time machining composites is also its last time. According to Dr. Jack DeLuca, president and COO of Amalga Composites, there are two common reasons why shops could go one-and-out versus composites.

It is important to accurately track a tool’s machining time no matter what type of tool material is used. HSS, carbide and diamond tools all wear down and shrink in diameter; an operator can trend and react to this. When a tool begins to lose its sharpness, it tends to catch fibers without breaking them, pulling and unwinding fibers from the part instead of cutting them. It takes diligence on a machine operator’s part to know what a tool’s predicted effective life is and change the tool before dulling occurs (usually after a certain number of machining operations are performed). In machining composites, tool life is predictable as long as there hasn’t been a change in the part’s resin, fiber or fiber-winding angle.

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

AI technology isn’t just a concept for the future—it’s here now, ready to transform your estimating process with the new AI BOM builder in JobBOSS². In this first-launch webinar, discover how AI can revolutionize bill of materials (BOM) entry in your shop, saving time, reducing errors and boosting efficiency. In this session, ECI will review how to use AI to build BOMs through a powerful feature that automates the extraction and input of BOM data from PDFs, Excel spreadsheets and images, all within JobBOSS². You'll have the opportunity to watch a live demonstration of the AI BOM builder in action — showcasing its ability to reduce BOM entry time from hours to mere minutes — thereby allowing you to focus on more strategic tasks. Additionally, you will learn about the real-world benefits of AI-driven BOM entry, including the minimization of manual errors, enhanced accuracy, and streamlined estimating processes — all of which can provide your shop with an immediate competitive edge. Finally, there will be a Q&A session with experts, giving you the chance to ask questions and find out how to integrate AI effectively. Agenda: Experience AI in action in a real-world manufacturing setting Discover how the AI BOM builder can immediately impact your shop’s efficiency and productivity Get hands-on insights on implementing AI to streamline your operations

Compositemachinist jobs

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

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.

Known for our custom performance vehicles, we specialize in carbon fiber composite part manufacturing. CARBON FIBER components.

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

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

Coolant aids in dust control for operations such as centerless grinding that would create a tremendous amount of particulate. With an operation such as single-point turning, though, the dust is released in a finite area, which allows easy collection by a vacuum system installed at the machine. Those operations will be performed dry unless workpiece or tool frictional heating is an issue.

The toggle clamps on this steel extension allow composite tubes to be installed in a lathe without damaging or distorting the part.

Manufacturer Name: Garr Tool Company ; Country of Origin: US ; Cutter Diameter: 12 mm ; Cutting Direction: Right Hand ; Finish: Alumastar Coated.

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?

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.

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.

The company’s raw composite tubes are created on precision chrome-plated mandrels, in which resin-coated fiber reinforcement is overlaid in cross-hatching layers (called lamina). Tubing wall thickness might range from 1/8 inch to 3 inches, depending on the application. A mold release agent applied to the mandrel aids in removing the tubes after curing. The raw tubes, which can vary in diameter from 1 inch to 42 inches, are then typically cut to length and staged for secondary machining operations.

As with other materials, drilling speed should be adjusted per the size and depth of hole—typically the bigger the hole, the slower the drill speed should be in order to maintain consistent feet per minute for the tool.

At Carnegie Mellon University’s Manufacturing Futures Institute, researchers use a robotic test bed where AMRs deliver Lego bricks to robot arms for assembly to study AI, multirobot collaboration, assembly, safety and more.

Face milling is a common operation for compression-molded parts. One example is a flange that is installed in the end of a drive shaft (see photo above). This component requires face milling to ensure flatness, as it will be bolted to a gearbox. Milling is performed using a face mill with diamond inserts from Valenite (Madison Heights, Michigan) on a tree vertical machining center (VMC). The company is investigating other milling machines for multiple-axis work.

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.

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.

Dr. DeLuca points to two myths regarding the machining of composites—1) you’ll ruin your machines and 2) the dust is dangerous to the operator. Neither is true. A machine running composites or any other material will only be ruined because of cutting debris if it is not cleaned on a regular basis. More frequent changes to filters on the electronics cabinets are recommended, though (monthly instead of twice a year).

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

In this episode of the AM Radio podcast, Robots & Autonomy Editor Julia Hider joins Additive Manufacturing’s Executive Editor Stephanie Hendrixson and Editor-in-Chief Peter Zelinski to discuss how robots and 3D printing enable each other.

Amana Tool CNC Face Milling for Non-Ferrous Metals End Mill/Router Bit ... inserts for maximum feed and stability, specially made for CNC and milling machines.

The Detroit Auto Show, formerly known as the North American International Auto Show (NAIAS), is located squarely at the intersection of technology and mobility. It’s a global event filled with tangible advances ready to hit the pavement today. Here, the software is as revolutionary as anything out there, and the hardware always looks better with a good polish. You won’t find any devices that will fit in your pocket, but you will discover machines that will move you in the most literal sense. You’ll also connect with thought leaders from around the world, both in and outside the automotive industry, whose collective visions for the future of mobility will shape the way we move for years to come.

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.

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

After the groove is cut the set screw in the side is reinstalled to lock the cutter bit back to the tool holder. The tool holder is then released by the set ...

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

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Coolant—The choice to machine wet or dry largely depends on the machining operation. Composite materials have low thermal conductivity, so coolant will be used for high-heat cutting operations to reduce the chance of degrading the part’s resin. Coolant also keeps cutting tool edge temperatures under control, which is especially important for diamond-coated tools to prevent the coating from releasing from the tool’s substrate. In addition to cooling cutting surfaces, coolant cleans a tool’s cutting surface, so grinding wheels, for example, won’t become loaded with material.

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.

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.

Spanning 113,500 square feet, the facility will centralize the company’s storage and distribution, as well as enhance operational efficiency.

It may be that the shop applies cutting strategies appropriate for aluminum or steel alloys, which simply won’t cut it for effectively machining abrasive composites. It also could be as simple as an operator’s flat-out refusal to deal with the dust and mess created when a cutting tool engages a part comprised of epoxy resin and fiber reinforcement.

No matter what your workholding application, automation always makes sense. Kurt Workholding helps you pick the right tool for the automation job — whether it be a single-vise setup or multiple vises holding large work pieces. This webinar will cover automation solutions using pneumatic, hydraulic and electronic actuation. Agenda: Most common types of vise automation solutions How to pick the right type of automation for an application Key differences between custom workholding and off-the-shelf automation solutions

Triple lead taps and dies cut a thread that engages in 3 separate starting positions. They are used for the cap thread of fountain pens and rollerballs.

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."

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.

There are two types of fiber reinforcement that the company uses for its composite products—glass and carbon. Glass is less expensive than carbon and is used for applications in which affordability and strength are required. Carbon is typically chosen for its stiffness—a carbon fiber part can be as stiff as steel at one-fifth of steel’s weight. There aren’t major machineability differences between the two fibers. Glass is more abrasive than carbon, which causes tools to wear faster. Carbon is more brittle than glass, and it makes a finer dust that can pose larger cleanliness issues.

The dust generated by machining composites is considered a nuisance dust (as is sawdust). While glass fiber is itchy, it’s not like asbestos fiber, which can attach to a person’s lungs. It is simply a matter of getting used to exposure to the dust. One of Amalga Composites’ current machine operators who had an allergic reaction to the type of coolant used at a previous shop isn’t bothered at all with composites dust.

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 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.

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

For machining operations that are performed dry, an effective vacuum dust collection system is used to limit any mess. While the dust does not pose a serious health risk, some operators will wear protective gloves and/or masks.

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?

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.

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.

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.

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

In this webinar, director of manufacturing Phil Linscheid will discuss how Hamilton Company has transformed its manufacturing operations with real-time production data. Learn how Phil and his team have increased throughput five times since 2017, while simultaneously improving production efficiency. Phil will share his journey over the past few years making strategic decisions to grow the machine shop’s impact as well as how his team uses MachineMetrics to improve production visibility, automate cycle time tracking, increase machine uptime and enable accurate quoting and planning. Agenda: Enabling production visibility in Nevada’s largest machine shop Improving quoting, planning and scheduling with accurate cycle times The importance of integrating shop floor data with operational systems

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

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.

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

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.

Workholding—To support long, thin tubes that require turning operations, headers that are just a few thousands of an inch smaller than a tube’s bore may be temporarily installed into either end for chucking purposes. Shorter tubes, perhaps those requiring only a facing, drilling or turning operation, might be mounted on a steel extension gripped by the lathe’s chuck. Toggle clamps on the extension hold the workpiece in place with sufficient force for the machining operation, but not so much force as to deform the part. Care must be taken not to scratch a tube’s inner surface when it is being held by its ID. The solution can be as simple as adding a layer of duct tape over chuck jaws.

Centerless grinding offers not only OD accuracy, but also a fast way to remove a lot of material. A grinding operation can take 0.01 to 0.025 inch for each pass. This is more than would be possible if grinding a steel tube because the composite material is less dense, allowing deeper passes. However, because the stiffness of fiberglass in the radial direction is 1/10 that of steel, there is some deformation, which means the composite tube OD can’t be as accurate as steel.

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

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.

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

Grinding—For most tubing products, their ID is more critical than the OD (the precision mandrel provides the accurate ID). Rollers, however, do require a precise OD. The company’s Cincinnati centerless grinding machines were modified to increase workpiece capacity from 6 inches to 22 inches to accommodate large rollers. Tubes that are larger than 22 inches in diameter will be ground on a large-capacity lathe. Nearly all tubing products are centerless ground using plain water for coolant and either silicone carbide or aluminum oxide wheels.

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Achieve higher metal removal rates and enhanced predictability with ISCAR’s advanced high-feed milling tools — optimized for today’s competitive global market.

While coolant helps contain dust, the resulting coolant/dust mixture is a slurry-like consistency. Composite dust is inert, so it can be landfilled. However, the landfills can’t deal with the excess water. Amalga Composites has equipment that removes water from the mixture, leaving behind a clay-like material that can be landfilled.

The toggle clamps on this steel extension allow composite tubes to be installed in a lathe without damaging or distorting the part.

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.

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

HSS, the least expensive of the three tooling materials, might be appropriate for very short runs where overall tool life isn’t as critical as a high-volume job. Carbide falls between HSS and diamond in terms of tool life and wear resistance, and it is used accordingly. Diamond-coated tools are the cutters of choice for most composites machining operations at Amalga Composites, as they offer the best wear resistance over many cutting operations.

Facing increasing competition from lower-cost imports, Suburban Tool made a move toward large-scale, in-house machining. By identifying a niche in large, precision angle plates and tombstones, the company has strengthened its ability to control quality and protect its reputation.

Fiber-wound products are analogous to wood, because both have a grain, grain direction and different strengths depending on those grain directions. Amalga Composites is able to design attributes into the filament-wound parts to facilitate secondary machining processes, as the material reacts differently to machining depending on the type of fiber reinforcement, winding angles and resin formulas.

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.

The company has found that it is typically easier to cut parallel to the length of the fiber, rather than across the fiber. That’s because the fiber, which essentially fractures as it is being cut, cleaves better along its length versus 90 degrees to the fiber. This leads to a smoother cut with less possibility for chipping.

Founded in 2001, PMTS reconvenes in April 2025 to celebrate its 13th biennial event for precision machining pros. Mark your calendar now and plan to join the precision machined parts community when we once again gather in person to share challenges and insights, see new technology solutions and learn about process innovations you can take back and immediately put into use in your own shop. The Precision Machining Technology Show is centered at the intersection of the industry's newest and most advanced product technologies, process innovations, business development prospects and personal career growth opportunities.

Heidenhain and Acu-Rite Solutions are offering several hands-on experiences at their booth this year, as well as internal components that reduce energy use.

The fiber reinforcement is the reason why composites are more stable than unfilled plastics such as nylon. So while bounce-back (deformation as a result of tool pressure) must be accounted for when machining non-reinforced plastics, it is not as big a problem for composites.

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.

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.

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

Composite machiningcompanies

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

Amalga Composites’ specialty is producing fiber-wound products, such as drive shafts, rollers, pressure vessels and tanks. It also compression-molds end caps for tubing products, as well as parts for aerospace, fluid power and other industries. Half of its manufacturing process is dedicated to winding or molding raw composite components; the other half is dedicated to machining those parts.

Chamfering—Highly accurate shouldering and chamfering operations might be performed on one of the company’s CNC lathes. Another alternative, depending on part quantities and tolerances, is a machine that resembles a router but uses a 23,000-rpm air motor to spin a solid carbide burr. A chamfering operation on this piece of equipment takes roughly 1 minute, versus 5 minutes on one of the lathes.

Drilling—Hole drilling is a common operation for the company’s tube parts, and it is performed on both the lathes and on the VMC. Clean holes are required for the tubing section of pressure vessels, for example, to accommodate a bulkhead fitting for condensate drain or other fittings. Supporting a tube’s inner wall is critical when drilling through the thickness of a tube to prevent delamination, or separation of the fiber layers. A wooden or plastic plug temporarily installed inside the tube is typically used to provide requisite wall support.

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

Flex Machine Tools’ Open House event will take place Thursday, December 5 at the company’s headquarters in Wapakoneta, Ohio. It will feature a facility tour and live machining demonstrations.

Tooling—Composites are inherently abrasive and cause cutting tools to wear rapidly. Depending on the circumstances, high speed steel (HSS), carbide and diamond-coated cutting tools are all viable choices for machining composites. Regardless of the cutting tool’s material or coating, its geometry should have a positive rake angle. A positive cutting edge tends to knife its way into the material. This shears the fibers more effectively than negative or neutral profiles that rub or drag across the material.

Milling—Milling operations are typically performed on compression molded parts, rather than tubes. In general, milling techniques are similar to those used for marine brass, which require sharp tools and a positive rake angle. Machining speeds and feeds are three times faster (900 feet per minute) for compression molded parts because the material makeup is different from fiber-wound parts. The fiber volume of a compression-molded part is typically 60 percent, and the fibers are relatively short (approximately 1 inch in length). This allows easier cutting than a tube that has fibers wound continuously throughout the part. The tubing parts also have higher fiber content (70 percent), so much more fiber must be cut.

Turning—The company has a few lathes, including a small slant-bed machine from Okuma (Charlotte, North Carolina) and a larger CNC lathe with live tooling from Toolmex (Natick, Massachusetts). The Toolmex machine is used for both long and short tubes. For tubing parts, machining operations include turning to diameter, grooving, facing ends, boring and slotting operations. Regardless of the machine, the company shoots for a surface speed of approximately 300 feet per minute when turning. Most parts are turned using diamond inserts.

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Standard metalworking equipment can be used to perform milling, turning, grinding and other operations on abrasive composite materials. The key is to match the process variables to the material.

Keeping Busy Amalga Composites is busier now than it has ever been. The pace is not likely to slow down anytime soon, as composites are gaining greater acceptance for applications that previously used steel or aluminum. This is because of the material’s resistance to corrosion and chemicals. To make sure the company keeps up with greater demand, it has started implementing lean manufacturing techniques such as 5S to speed and streamline its manufacturing processes.

Solid carbide profile tool is a good choice when fine detail is needed. It has a single lip cutting edge that cuts clean in wax and other soft materials.