Quick Change Tool Post - Lathe Toolholding - quick change tooling

2024-06-18 09:01:09

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

Cutter speed is the major influence in creating heat at the cutting edge of the tool. Maintaining a high chip load or feed is how heat is dissipated. Correct ipt, combined with the right cutter rake angle for the material being machined, produces a chip of sufficient density to carry heat from the cutting zone so work hardening can be avoided.

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.

The choice depends on the material and application. Climb milling is generally better for softer materials and smooth finishes, while conventional milling offers more control for harder materials.

The climbward force in climb milling presses the workpiece against the machine bed, which helps improve stability during the cutting process. This reduces the risk of vibration or movement, ensuring greater accuracy in the final product.

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.

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.

Climb milling provides a better finish because it minimizes tool deflection, reduces friction, and generates less heat, which leads to a smoother surface.

Starting with HSS and progressing to diamond and CBN coatings, a scale can be built progressively from best toughness characteristics to best thermal hardness. High speed steels take a pounding but can't take much heat. Ceramics and diamond coated cutters can take the heat but fracture easily.

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.

Chip load is feed rate for each cutting edge of the tool. For indexable insert tools, it's the load against each insert. On solid body cutters, chip load is rated against each tooth. According to Mr. Spanovich, a good working range of chip load is generally between a minimum of 0.003 ipt to a maximum of 0.012 ipt.

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

Choosing between climb milling and conventional milling is essential for optimizing your CNC machining operations. While climb milling offers a smoother finish, longer tool life, and lower heat generation, conventional milling excels in stability and control, particularly when working with harder materials. Understanding the strengths and weaknesses of each method allows manufacturers to select the best process for their specific applications, ensuring efficiency and precision in every project.

Negative rake tools have a much stronger leading edge and tend to push against the workpiece in the direction of the cutter feed. This geometry is less free cutting than positive rakes and so consumes more horsepower to cut.

There are usually better solutions to chatter than just reducing the feed rate. Through vibration analysis, the chatter problem can be solved, enabling much higher metal removal rates, better quality and longer tool life.

At elevated cutting speeds and feeds, coolant may be less necessary than at conventional speeds. Heat is the by-product of machining. Generally it's the enemy of metalworkers. Increasingly however, heat is being used to help the cutting process.

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

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

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%.

Climb milling isalso known as

These rates represent optimum cutting potential for the right combination of workpiece material and cutter material. However, there are other factors that must be considered before a shop can hope to approach these kinds of cutting speeds.

In the world of CNC machining, choosing the right milling process is critical to achieving the desired surface finish, tool life, and overall efficiency. Two common milling techniques used in CNC machining factories are down milling and reverse (conventional) milling. While both methods are effective for cutting materials, they differ in terms of how the tool engages with the workpiece and the direction of the cutting forces. Understanding the differences between down milling and reverse milling helps manufacturers optimize their operations and make informed decisions in custom CNC machining projects.

There are no specific formulas to determine the best combinations and results. It takes a little experimentation to find optimum feeds and speeds for a specific application.

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.

While climb milling is generally preferred in CNC machining, there are certain situations where conventional milling offers significant benefits.

To get perspective on tooling considerations for high speed machining, we contacted Kennametal (Raleigh, North Carolina) to discuss high speed cutting tools.

"In the mean time, shops looking to do high speed machining on their machining centers may be better off specifying AT3 or better V-flange tooling than waiting for an HSK standard tooling configuration," says Mr. Lewis. It could be a while before HSK or an equivalent standard for tool, spindle and gages comes along.

Choosing between climb milling and conventional milling depends on several factors, including the material type, desired surface finish, and the specific requirements of the project. Here are a few tips to keep in mind when selecting the right milling technique:

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?

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.

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

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.

What is climb millingprocess

At the seminar, representatives from multiple companies discussed strategies for making orthopedic devices accurately and efficiently.

In an ideal cut, workpiece material, machine feeds, spindle speeds and cutter are all making their respective contributions in optimum fashion. As the cutter creates a chip, the heat generated by that action is transferred to the chip. When the chip breaks and leaves the cutting zone, the heat is carried away with it.

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

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.

By equipping MassRobotics with its advanced cobots, ABB aims to facilitate the creation of new and impactful solutions that address real-world challenges across various industries.

Climbvs conventionalmillingsurface finish

A big advantage of high speed machining is that at elevated rates of speed and feed, the chip is cut and evacuated so fast it tends to transfer little or no heat to the green workpiece. At conventional machining speeds, there is time for heat to move from chip to uncut metal and create a work-hardening condition. This increases the force needed to create a chip, which creates more heat, and on it goes. Coolant mitigates the cycle by reducing the temperature in the cut zone and flushing away the chips.

There is no one-size-fits-all answer. Climb milling is best for smoother finishes and longer tool life, while conventional milling is more suitable for hard materials and increased stability.

Commercial considerations are also driving shops toward higher rates of productivity. The need to put more work across machine tools has shops looking constantly to improve metalcutting processes.

The lower cutting force and reduced heat generation in climb milling lead to longer tool life. Since the tool is less likely to overheat or experience excessive friction, it retains its sharpness and cutting efficiency for a longer period, reducing the need for frequent tool changes.

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.

The importance of rigid fixturing cannot be overemphasized in high speed machining applications. While the goal of any fixturing or clamping setup is to hold a workpiece securely and allow for repeatable location of subsequent parts, high speed requirements magnify any imperfections in a workholding setup.

Climb milling is better when you need a smoother surface finish, lower heat generation, and longer tool life, especially when machining softer materials.

The angle of attack for the cutter edge, its rake angle, influences the chip load for a cutter. Rake angles vary from positive through neutral to negative. Positive rake angles present a sharper edge to the workpiece. It's also a weaker edge. Positive rake tools tend to pull the workpiece toward them during the cut. They also tend to push chips up and away from the cutting zone.

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."

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.

Conventional milling provides a zero-clearance cut, meaning the cutter doesn't engage in any pre-machined surfaces. This can be useful for operations where you want to avoid unnecessary contact between the tool and finished surfaces.

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.

Successful high speed machining is dependent on static and dynamic rigidity among the many components that bring together the tool and the workpiece. Critical to this is a highly rigid connection between the tool, toolholder and the machine tool spindle.

So, we're not going to assign a definitive value to high speed. Suffice it to say high speed machining means cutting metal faster that is customary for your operation.

Conventional milling provides more stability when working with hard or abrasive materials. The cutting tool engages the material more gradually, which can help reduce the risk of tool chatter and maintain steady cutting conditions, especially for heavy-duty machining operations.

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.

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.

In high-volume production environments where tool life is critical, climb milling can help minimize tool wear and reduce climbtime for tool changes.

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

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

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.

If you are working with hard materials or heavy cutting loads, conventional milling may provide better control and reduce the risk of tool chatter.

High speed tooling geometry, in general, mirrors the geometry of conventional machining. "What you know about tool geometry for conventional machining transfers to higher speed applications," says Mr. Spanovich. "If there is a trend in high speed, it is toward a positive lead angle tooling. This lead angle effect allows greater ipt, by lifting the chip, while maintaining the same chip thickness. This greater feed rate results in higher speed machining.

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?

Implementing higher speed machining in a shop has many benefits, some obvious but others less so. Obviously, making parts faster helps satisfy customers' demands for quicker deliveries despite shorter lead times. There are also benefits derived from increased tool life. It may seem paradoxical, but machining at high speed with the right tooling matched to the application can reduce tool wear because of the diminished cutting forces at high speed.

Since conventional milling engages the material more aggressively, it offers better control over the cutting depth. This is especially useful when making initial cuts or working with materials that tend to push back against the tool.

Advantages ofclimb milling

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Generally, tungsten carbide cutters have a working range of 100 to 1200 sfm, according to Mr. Spanovich (HSS goes up to approximately 100 sfm). Ceramics, including silicon nitride, push the envelope up to 4,000 sfm. Polycrystalline diamond and CBN coated tools push sfm above 4,000. These rates are at chip loads of 0.003 to 0.030 ipt.

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.

Conventional milling generates more heat due to the higher cutting forces. This can be problematic when working with heat-sensitive materials, leading to warping or material deformation.

"The problem with HSK," says Mr. Lewis, "is no governing body has established a standard for tooling companies to manufacture to. There is a German DIN standard that's being considered by ISO but so far it has not been approved. There are also some challenges to HSK from Japan, other European countries and the United States. The question of what HSK will look like is not yet decided.

At VMT, we specialize in offering high-quality custom CNC machining services tailored to meet the unique needs of our clients. Our advanced milling technology and experienced team can handle both climb milling and conventional milling techniques, ensuring that your parts meet the highest standards of precision, durability, and surface finish.

In high speed machining applications, the fixture should support the workpiece on a solid base and have enough mass to help damp cutter-induced vibrations. Fixtures for high speed need not be overly complex but should follow good shop practice.

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.

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

Despite their advantages, both climb milling and conventional milling come with certain limitations. Knowing these drawbacks helps ensure the right method is chosen for your specific CNC machining application.

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.

Choose conventional milling when working with hard or abrasive materials, or when you need better control over the cutting forces, such as in heavy-duty operations.

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.

While much of the discussion about high speed machining tends to focus on the role played by the machine tool, the cutter is its partner in high speed machining. And, that's the focus of this article. We're going to look at what a shop needs to know about specifying cutting tools for their high speed applications.

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

A cutting tool material has specific attributes that make it usable in a metalcutting application. Because applications vary so widely, there are many cutting material combinations from which to choose.

Metal removal rates are faster today than ever before. What was considered high speed machining just a few years ago is regarded as conventional today. Many factors are driving shops to faster metal cutting rates. These include better and more capable machine tools and CNC processors that allow the machine to accurately cut at increasingly higher speeds and feeds.

In conventional milling, the cutting force starts with a thinner chip and increases as the tool moves forward, leading to higher cutting forces.

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.

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.

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

What isconventionalmilling

Conventional milling, also referred to as up milling or conventional milling, involves the cutting tool rotating in the opposite direction of the workpiece feed. In this method, the cutter’s rotation is against the direction in which the material is fed. This means the tool engages the workpiece at the thinnest point of the material and gradually cuts into thicker sections, resulting in an increased cutting load.

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.

Climb millingvs conventional

"The formation of a sufficiently thick chip is the goal," says Mr. Spanovich. "The idea is to use chips as a heat sink. Faster speeds make more heat, so directing that heat into chips becomes critical in high speed machining applications."

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

Since the chip thickness decreases during the cutting process in climb milling, the cutting load is lighter, and the process generates less heat. This is particularly beneficial when machining heat-sensitive materials or when producing precision parts that require tight tolerances.

There are several key distinctions between climb milling and conventional milling that influence which method should be used in CNC machining services. These differences include the direction of tool rotation relative to the feed, the cutting forces involved, and the impact on surface finish and tool life.

This article will delve into the distinctions between climb milling and conventional milling, discussing their advantages, disadvantages, and best-use cases to help you determine which process is ideal for your next CNC prototype machining or production project.

The primary difference between HSK or other hollow shank, short taper toolholders is the way the tool fits into the machine tool spindle. HSK uses a simultaneous fit between the short taper and the face of the spindle. The connection is very rigid.

Whether you're working on a CNC prototype machining project or require large-scale production, we provide the expertise and equipment necessary to deliver exceptional results.

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.

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.

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.

Climb milling is not always ideal for machining extremely hard or abrasive materials, as the cutter may struggle to penetrate the material smoothly without excessive tool wear.

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

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.

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

Yes, climb milling typically results in less tool wear because of the reduced cutting forces and heat generated during the process.

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.

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.

High speed machining can help a shop manufacture more accurate parts with better surface finishes. Often, because a machine tool and workpiece setup must be very rigid for high speed machining, the results are more consistent workpieces.

Thermal shock is another consideration for users of high speed tools--especially ceramic and harder cutting edges. Irregular distribution of coolant in the cut can create an unstable heat zone for these cutters. Designed to operate at elevated temperatures, the cutter material can undergo successive heat and chill cycles in the cutting zone that can create premature failure from thermal shock.

Much has been written about HSK or equivalent tooling as a possible replacement for the V-flange connection in machining operations. "While there are some advantages to the design concept," says Mr. Lewis, "its widespread application is being held up in part by a lack of manufacturing standards."

Climb millingdirection

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

Indexable insert tools for high rpm are different than tools for conventional rotating speeds. Inserts are secured differently to the cutter body for high speed indexable tools. According to Mr. Spanovich, a simple setscrew clamp is not adequate for high rotation. Inserts are secured to the cutter body with a pin that fits into a detent molded in the insert. It is anchored on the cutter body in a direction perpendicular to the centrifugal forces generated by rotation.

Climb milling can result in tool bounce, especially if the workpiece isn’t securely clamped. This can negatively impact precision, leading to inaccurate cuts or a poor surface finish.

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

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

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

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

Due to the higher friction and cutting forces, conventional milling can leave a rougher surface finish. This is particularly true when machining softer materials where the tool can leave visible tool marks.

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.

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

The V-flange taper connection is a potential source for high speed vibration. Until recently, the V-flange taper and measurement gages used by cutting tool manufacturers were made to ANSI/ASME B5.10 standards. "Until high speed applications came along, the ANSI/ASME standard worked well," says David Lewis, staff engineer for Kennametal and vice chairman of the ANSI/ASME B5 standard committee.

A generic definition of high speed machining is elusive. High speed is relative. What's very fast for one industry segment seems glacial to another.

In the world of CNC machining, choosing the right milling process is critical to achieving the desired surface finish, tool life, and overall efficiency. Two common milling techniques used in CNC machining factories are climb milling and conventional (conventional) milling. While both methods are effective for cutting materials, they differ in terms of how the tool engages with the workpiece and the direction of the cutting forces. Understanding the differences between climb milling and conventional milling helps manufacturers optimize their operations and make informed decisions in custom CNC machining projects.

For softer materials and projects requiring a smooth finish, climb milling is typically the better choice due to its smoother cutting action.

Conventional milling tends to generate more heat and friction between the tool and the material, which can cause surface roughness and excessive wear on the tool. However, it can offer advantages when working with certain materials and for specific operations where greater stability is needed.

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

Machining speed is very application specific. Calling a machining process high speed draws a comparison between its current and previous performance capabilities. For example, high speed might mean changing from an HSS tool to solid carbide, which allows you to bump up machine feeds and speeds. Because carbide cutters, in many applications, can remove metal faster than HSS, a shop using carbide is machining faster compared with HSS rates. But it's relative because another shop, using cermet or ceramic cutters, can cut faster than carbide.

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.

The reason is simple centrifugal force. For the same reason tire manufacturers have speed ratings for radials, tooling manufacturers put a "not to exceed" rpm on cutters. The force created by rotating a body is exponential to the speed of rotation. That force is trying to rip the inserts away from their seats. Any part of a cutter flying off at 10,000, 15,000 or 20,000 rpm poses a risk to life and limb.

These two measurements are dependent on each other to determine the speed at which a workpiece can be maintained. For example, titanium can be cut effectively at about 250 sfm. That's using a chip load of 0.005 ipt. However, some shops report machining titanium at close to 500 sfm, but to do that, lighter chip loads are taken.

Elusive as high speed machining is to define, there are measurements used for machining speed. These allow comparison between different rates and help a shop determine its place in the machining speed continuum.

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.

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

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

In climb milling, the cutting tool engages the workpiece more smoothly, which results in a finer and more uniform surface finish. The climbward cutting motion minimizes the risk of surface tearing or roughness, especially when machining softer materials.

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.

Depending on the cutter material, chip load and surface speeds can be adjusted to deliver the best combination for a shop's application. If heavy metal removal is the goal, cranking up the chip load and sfm will maximize the cutting efficiency. For better finish, backing off the chip load while keeping sfm up will give good surface finish.

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.

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

Fast CNC processing and high-pressure coolant contribute to removing metal at dramatic rates. But what should a shop know about cutting tools in high speed machining?

Taper fit between a tool body and the machine spindle can be in tolerance (per ANSI/ASME B5.10) and still cause runout and eccentricity problems for a high speed cutter. Mr. Lewis and others representing U.S. tooling manufacturers recommend application of the European ISO 1947 AT3 standard in place of ANSI/ASME B5.10. The ISO standard has twice the accuracy requirement of ANSI/ASME and results in a better connection between the spindle taper and the V-flange tool. To make sure the tooling you purchase for high speed applications is made to the new standards, specify ISO 1947 AT3 or equivalent from your tooling manufacturer for toolholders and collet chucks. For machine tool spindles, specify ISO 1947 AT2 (a lower AT number means a better fit). Mr. Lewis recommends gaging be acquired to check spindle and tool tapers in the shop.

Climb milling is also called climb milling because the cutter "climbs" over the material as it cuts, with the tool rotation and feed direction moving in the same direction.

Milling can be expensive due to the high precision required, tool wear, setup time, and the cost of CNC machining equipment and skilled labor.

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Adopting PCD tooling has extended FT Precision’s tool life from days to months — and the test drill is still going strong.

But at very high rpm, the tool rotation throws coolant away from the cut zone so without very high pressure or through-the-tool piping, it never reaches the cutting zone. "In some cases," says Mr. Spanovich, "trapped chips can remain in the cut, allowing them to be recut by the tool. We've found an air blast is very efficient for evacuating chips in high speed applications."

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Each milling method has its own set of advantages, which make it suitable for different types of machining operations. Below is a breakclimb of the benefits of climb milling and conventional milling in custom CNC machining.

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

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, feed rate for the machine tool is usually measured in inches per minute (ipm). But for cutting tools, it is expressed as inches per tooth (ipt). Working from the optimum sfm and ipt for workpiece material, a machine tool's rpm and ipm can be determined and programmed.

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In some cases, particularly with harder materials, climb milling may cause excessive vibration. This can reduce the accuracy of the machining process and lead to premature tool wear.

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Climb milling is typically preferred in CNC machining due to its smoother cutting action and reduced heat generation. This method results in less friction between the cutter and the workpiece, which can improve tool life and provide a better surface finish.

For example, a good vise is adequate if it supports the workpiece securely. It is recommended that positive stops be used to prevent torquing or movement of the workpiece in response to cutter motion.

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What is climb millingmachine

Proper selection of a cutting tool, especially an indexable cutter that is rated to spin at elevated speeds, is important. Not to put too fine a point on it, but we're talking potentially serious or even fatal accidents if a shop tries to exceed tooling speed ratings.

Cutting tool materials can be classified into five general categories. The materials are arranged from best toughness characteristics to best thermal hardness:

Tool balance becomes a big issue at high spindle speeds. "We recommend smooth shank tools, for end mills and drills, held by a hydraulic or roll-lock collet chuck for high speeds," says Mr. Spanovich. "Balance becomes an issue at 5,000 rpm and up. At those speeds, a notch shank with setscrew can move the tool enough off-center to induce vibration--hence chatter." For speeds of 20,000 rpm and up, a custom balance of tools and toolholder combination is recommended.

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.

A less obvious benefit of high speed machining for shops moving in that direction is derived from the exercise of implementing it. Learning to do the things necessary for successful high speed machining can simultaneously elevate other facets of an enterprise to equivalent levels of productivity.

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?

For precision machining requiring tight tolerances, consider using climb milling to reduce the risk of tool deflection and achieve a finer surface finish.

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Climb milling, also known as climb milling, is a machining process where the direction of the cutter’s rotation is the same as the feed direction of the workpiece. In other words, the cutting tool rotates in a way that it pulls the material toward itself as the workpiece moves forward. As a result, the tool starts cutting at the thickest point of the material and gradually reduces the chip size as it completes the cut.

But in general, only two performance criteria are used to determine the applicability of a cutter. These are toughness or resistance to fracture (ductility) and thermal hardness (resistance to heat). A myriad combination of coatings, substrates and base materials can be created to deliver specific proportions of toughness and thermal hardness to fit various applications.

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In conventional milling, the tool rotates in the opposite direction of the material feed, leading to more aggressive engagement with the workpiece.

The aggressive nature of conventional milling can lead to faster tool wear and potential damage, especially when cutting hard materials at high speeds.

To quantify how fast a machine actually cuts metal, spindle rpm needs to be converted into something more useful. According to Dan Spanovich, application specialist for Kennametal, this figure is expressed as surface feet per minute (sfm).

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

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.