With its unique properties, tungsten wire is used in a wide range of industry applications, from tungsten filament wire bulbs to tungsten thermocouples.

Learn how tungsten as an alternative to precious metals can help you achieve uncompromising quality and still keep your budget on track.

OD grinding is used to shape the external surface of objects between the centers and excels at removing circular defects and restoring or creating roundness.

However, total runout tolerance is still very important for preventing vibration, oscillation, and surface taper on rotating parts that have large areas of surface contact, such as large pump shafts, transmission shafts, and complex gears.

Learn how additive manufacturing (AM) — one of today’s fastest growing technological innovations — is changing the face of contract manufacturing everywhere.

High precision internal grinding methods such as ID grinding and honing are used to achieve smooth finishes and tight tolerances on bore, hole, and tube IDs.

Another issue is that a machinist will often receive an engineering drawing that specifies a TIR value — but the drawing does not make it clear what exactly that means. For example:

Double disk grinding provides dimensional accuracy for metal part applications that require tight tolerances, parallelism, flatness, and thickness control.

Industry Trend No. 1: Increased exporting and global trade has a positive impact on revenue, growth, and competitiveness, while expanding a manufacturer’s customer base.

Metal tubing continues to play a critical role in medical device manufacturing, but with the array of available plastic materials it can be hard to determine which material is the right one.

Unfortunately, consistent results aren’t always guaranteed. Learn what you can do to ensure calibrated measuring yields accurate results.

Learn how precision cut off and stamping compare in achieving distortion-free flatness, a sharp edge, and the precise exterior diameter needed for a spacing ring.

Surface finish requirements are just some of the details critical to completing an RFQ that will help you optimize for manufacturability.

Often simply called runout, circular runout specifies how much the feature can vary in relationship to a reference point as the part is rotated around an axis. In basic terms, that means it looks at how much “wobble” there is in the feature of the part in relation to the reference point.

Get an expert machinist’s perspective on how CNC metal cutting has evolved in the age of tight tolerance, micro-machining of small parts.

Eddy current testing is an important method of nondestructive testing. See what you may not have known about the process.

Learn how better materials for resistance welding electrodes speed up your welding operation. This white paper is designed to help you make a successful electrode materials choice.

Learn how the right electrode material, design, and construction can help to prevent bonding problems in resistance spot welding electrodes.

Learn about the important role of machining and tooling in the manufacture of metal parts for today’s fuel injection systems.

Both circular runout and total runout are frequently used where you have components that must rotate quickly, such as drills, gears, shafts, and axles. That being said, a total runout tolerance is not called out as often, because it puts tight constraints on the entire surface of a part.

Here at Metal Cutting, where every day we produce thousands of small metal parts, one of the first things we do when we see a drawing with TIR values for circular runout and total runout is evaluate whether our equipment is capable of producing the customer-specified values.

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When measuring the perpendicularity of small metal parts, consider the effects of a part’s diameter, length, straightness, and manufacturing method.

Learn why resistance welding electrodes require a material with the right combination of thermal conduction, electrical resistivity, and reactivity.

The metal shearing process can be quick and inexpensive for cutting some simply shaped parts, but it has disadvantages including burrs and end deformation.

Get answers to common questions about dissimilar metals regarding high and low conductivity electrodes and friction stir in the construction of an electrode.

How do you qualify a new sourcing partner and ensure an efficient and problem free experience? Considering these points will help you make a decision you can feel confident about.

In the end, remember that total runout controls the total 3D surface of an entire part while circular runout only controls specific circular, 2D cross sections. And whichever feature is most appropriate for your application, choosing the best production method is critical to meeting your specified tolerance and ensuring your product achieves the desired functionality.

Utilizing a controlled environment helps to minimize the effects of heat expansion and other temperature issues on the measurement of metal parts.

Learn how the properties of copper tungsten reduce or eliminate the challenges posed by those materials when they are used in their pure forms.

Consider the methods used for heat treating metals, as well as the effects, when specifying your requirements for the cut-off of small metal parts.

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The electrochemical grinding process is a highly specialized method that combines surface grinding, chemistry, and fixturing, and has limited applications.

Gold-plated tungsten wire is useful in filtration, printing, copying, and other applications, and as an alternative to precious metals in some medical devices.

GD&T tolerances provide manufacturing guidance that must balance the need to make a part functional with the need to produce the part cost-effectively.

Precision tubing plays a vital role in helping to ensure the accuracy of liquid dispensing systems used in many biotechnology and laboratory environments.

A forming countersink tool for the punch press is made to your exact specifications and produces a clean countersink in seconds. It eliminates the labor-intensive drill and deburr operations. This cuts your production time by 50% or more.

It’s critical to choose a supplier you can envision working with for the long haul. Review these practical guidelines to make the right decision.

This method allows you to determine the total indicated runout (TIR), or the total amount the gage moves. If, for example, the gage moves 0.001” (0.0254 mm) across the part and that value is within the allowed tolerance, then your part meets that specification.

The Swiss machine has evolved and improved since the original Swiss lathe was invented, making the modern method an important part of precision CNC machining.

While laser cutting can produce a small kerf and tight tolerances, other precision cutting methods may be preferable for 2-axis cutoff of small metal parts.

As the name implies, circular runout is typically used to control variation in circular features of a part, such as shoulders, tapers, and fillets. In the GD&T system, the circular runout symbol is an arrow.

That means total runout seeks to limit the cumulative variation across an array of part surface characteristics, such as:

Learn more about the principles of centerless grinding and how it can be used to achieve tight tolerance surface finishes on small cylindrical metal parts.

Countersinkingtools

May 5, 2018 — 3. CONTINUOUS CHIP WITH BUILT-UP EDGE • When machining ductile materials at low.

Learn 7 simple rules to help ensure that calibrated measuring yields accurate and consistent results for your small parts manufacturing.

Choosing the right resistance spot welding electrode for an application depends on understanding critical properties of the different electrode materials.

Metal Cutting’s methods for cutting metal tubing, such as thin wall steel tubing for medical devices, are unique compared with machining and laser metal cutting.

With the eddy current testing ‬procedure, there are a number of variables that ‬have an effect on ECT, what it can find,‭ ‬and ‬what it cannot find.

For some medical device applications requiring biomaterials, tungsten and gold-plated tungsten wire may be suitable alternatives to precious metals such as gold.

Learn the vital components of an effective quality control program and its role in ensuring metal parts meet their requirements for design and function.

Industry Trend No. 2: Manufacturing globalization and regionalization provide opportunities for partnership, innovation, competitive advantage, and growth.

Small gages such as pin gages or pin plug gages are useful tools for inspecting IDs and making sure small diameter metal tubing meets specified tolerances.

Metal Cutting utilizes lapping and machining as well as other techniques to achieve flatness vs. parallelism for metal cut to length.

Learn the key parameters for choosing a method of 2-axis precision cut off of metal parts based on part type, material type, and part dimensions.

GD&T cylindricity is a three-dimensional tolerance feature used to indicate both roundness and straightness along the entire axial length of a cylindrical part.

Learn why manufacturers, designers, and engineers need to keep metal expansion from heat in mind when they create part specifications and decide how precise the part’s dimensions need to be.

Precision flat lapping and other lapping techniques can be used for small parts requiring tight control of surface finish, flatness, thickness, and parallelism.

Over time, we’ve developed a special appreciation for tungsten and what it can do. Learn some interesting facts you may not have known.

A fully complete RFQ tells a story about the buyer, the company, and the end product and its use — information we can use to provide the right quote (and the right price).

The old way to make a countersink was a three-step process: punch the hole, drill the sink, deburr. Three-step processes like this cost unnecessary time and money.

Cold sawing can do high-speed, burr-free cutoff of rods, tubes, and extrusions, but it is not ideal for very short lengths, smalls ODs/IDs, or hard metals.

Waterjet cutting is typically used to cut complex shapes from large, flat sheets of metal but may not be the best choice for 2-axis cutoff of small parts.

Calibration standards for devices and equipment used in measuring, inspecting, and manufacturing of precision metal parts can pose some unique challenges.

For tips on how to improve the accuracy of your specs and project quotes, download our free guide, How to Fine-Tune Your Quote Request to Your Maximum Advantage: Frequently Asked Questions in Small Parts Sourcing.

Finding a supplier who can deliver quality and on-time service can be tough, especially when it comes to the medical device and other heavily regulated industries. This guide makes it simple.

For EDM electrodes, copper tungsten offers excellent electrical conductivity, DC arcing resistance, thermal conductivity, and wear resistance.

Countersinkingand counterboring

Our name might not give it away, but precision cut off of tight tolerance, small metal parts is at the core of our business.

For deburring of small metal parts, mass production requires the action of hand tools to be re-created by mechanical devices suited to high-volume applications.

Countersink screw

Aluminium routers high productivity cutters are designed to provide optimal performance in slotting, square shoulder milling and pocketing operations in ...

Specifying the magnification level and details of how a material surface must be examined helps to ensure that parts will pass inspection and meet your needs.

A coining countersink tool is ideal for thicker material because it presses the material into the final shape. These excel at holding a tight hole tolerance. Available to form down, with interchangeable inserts for fast size changes, and in the self-stripping form-up style.

Surface finish requirements are among the details that are critical to creating a complete RFQ that will help to optimize for manufacturability.

Learn some common myths about plastic and reasons why it may not be a better choice than metal tubing for medical device applications.

The process of creating a vacuum atmosphere, either repeatedly or in one-time production, is an important part of electronic component manufacturing.

Learn how best practices as well as material and design considerations have an impact on the life and effectiveness of resistance spot welding electrodes.

Exploded Groove Profile & Edge Margin (Y). Maximum bottom radii (R), sharp corners for ring sizes -12 thru -23; .003 for ring sizes -25.

The key to calibration tolerance is understanding both what a device is capable of doing and the tolerance to which the device has been calibrated.

Countersinkingbit

Surface flatness is an indicator of all points along a surface lying in the same plane, with the highest and lowest points within the flatness tolerance range.

In this blog, we take a look at two related GD&T features that are sometimes called out on engineering drawings. For those of us who cut and machine small metal parts, the concept of circular runout versus total runout is not as simple as it may at first seem.

Learn more about Metal Cutting’s certification in the ISO 9001:2015 standards and commitment to quality management practices.

Learn why infiltration, density, and other properties of an alloy such as copper tungsten are important to  the quality of spot welding electrodes.

While automation plays a growing role in precision machining, lights out operation is still more a fantasy than a reality for most small part manufacturing.

How does laser cutting compare with other precision metal cutting methods? Watch this video to learn some of the pros and cons of this metal cutting method.

Any surface will have flaws under the right magnification. In this video we explain the inherent challenges with blanket requests and how to overcome them.

How to countersink screws without bit

Adherence to ISO 9000 standards by an organization tells customers that it is committed to implementing structured quality management practices.

And for the manufacturers who ultimately use the parts we make as components in their own products, understanding the difference between circular runout and total runout can be important to creating specifications that will yield the best results.

A forming countersink tool works best on thinner materials as it bends the material into the hole to create the “sink.” Like coining countersink tools, these are available to form down with interchangeable punch-tip inserts for cost savings and flexibility and in the self-stripping form-up style.

Industry Trend No. 3: Rising labor costs overseas are one factor in the move away from outsourcing and toward reshoring of some businesses and factories.

Learn about the five major challenges to consider when choosing CNC machining services and a partner for the manufacture of complex and precise small parts.

What, then, is the easiest way to think of runout vs. total runout? Circular runout controls only a particular circular cross section of a part, while total runout controls the entire surface of the part.

Learn the advantages of copper tungsten electrodes for resistance spot welding of wire harnesses in battery electric vehicles (BEVs).

While an automatic lathe can do simple 2-axis cutoff of metal rods and tubes, it is designed for more complex, multi-step machining operations.

Tungsten, also known as wolfram or volfram, has a high melting point and other interesting properties that are useful in many industries and products.

Countersinkingdrill

Copper tungsten electrodes combine the thermal resistivity of tungsten with copper’s resistance to DC arcing, making them a smart choice for EDM of carbides.

It may be tempting to assume that a very tight tolerance should be your default choice. But, when they aren’t essential, it could increase your costs needlessly.

The characteristics of the precision tubing used in liquid dispensing systems can significantly affect the fluid dispensing process and testing accuracy.

In circular runout vs. total runout, the first controls variation in circular features of a part while the other controls variation in the entire part surface. Learn the difference and how to measure them here.

Explore the advantages of pure tungsten and pure molybdenum as alternative materials for use in spot welding electrodes.

For instance, when you make something using a spinning device, there are typically TIR values for three different sources of wobble — the spindle, the collet (or chuck), and the cutting tool or drill itself — any or all of which can create errors in the part.

There are 5 key areas that should never be left blank when filling out your request for cutting quote. Do you know what they are?

Electrochemical cutting (ECC) combines electrochemical erosion and grinding to produce a burr-free, shiny surface to a tight tolerance of ±0.005” (0.127 mm).

In material sourcing for the production of precision parts, avoiding non-standard material sizes can help to control costs and optimize for manufacturability.

Different precision metal cutting options vary in characteristics and appropriate applications, making the choice not quite so easy. This guide will help.

When polishing metal parts for 3D printed medical devices, the goal is to achieve the proper surface finishes while maintaining the device’s complex design details.

Surface grinding services utilize precision surface grinding methods to make cubic metal parts square and parallel or the ends of metal rods perpendicular.

Incandescent bulbs made with tungsten wire filaments continue to be used in automobile turn signals despite the parallel adoption of newer LED technology.

The straightness properties of tungsten wire make it valuable for small diameter tungsten probes used in semiconductor wafer testing and neural activity testing.

What is lapping? In the right hands, this little-known process can produce parts with highly polished ends, tight length tolerances, and extraordinary flatness.

Learn the vital components of an effective quality control program and its role in ensuring that metal parts meet their requirements for design and function.

Providing all the details in an engineering drawing, including runout or total runout symbols and tolerances as appropriate, can help to alleviate confusion.

Thin-wheel abrasive cutting is an ideal method for high-volume 2-axis metal cutoff that requires precision, tight tolerances, no burrs, and a smooth end finish.

For intricate geometries, sharp corners, unparalleled wear resistance, excellent cutting speeds and machinability, copper tungsten is the material of choice.

Thousands of resin compounds have been developed to expand the design options for tubing in medical devices. Yet, there are number of myths. Learn why plastic may not be a better choice to metal tubing in medical applications.

Whether you are using a vertical mill or a lathe, the goal is to determine how balanced, accurate, and correct the spinning device is. The challenge is that everything in the machining business has a TIR.

With profile of a line vs. profile of a surface, the former controls variation at specified cross sections while the latter controls the entire feature surface.

When designing a part, remember that different tolerances may require different processes, and not all processes can produce results to the same tolerance.

Learn why the characteristics of titanium tube make it a good choice for medical devices and other applications that require strength, light weight, and corrosion resistance.

Deburring External Chamfer Tool, Hexagonal Shank with Carbide Insert Bit for Fast Grinding and Deburring, for 1/8" to 3/4" Countersink (Silver)

While graphite is often used, the properties of copper tungsten make it an ideal material for EDM electrodes for certain applications.

Dopants raise the recrystallization temperature of tungsten wire and other wires, giving non-sag properties to tungsten light bulb filaments and other products.

Laser printing of metal is popular for a number of applications, but can you‭ ‬use it for printing of metal for‭ ‬such large quantities of such small parts?

With a metric tolerance chart, you need to account for the upper and lower tolerance spec limits when converting between standard and metric measurements.

A metal surface finish chart is a handy guide to standard surface finishes and characteristics such as measurement units, conversions, and typical Ra values.

Learn about the variables to consider when choosing the best resistance welding electrode material for specific resistance spot welding applications.

Learn about the role that tight tolerance plays in optimizing for manufacturability, and how to specify tolerances to ensure part quality and control costs.

Aug 7, 2024 — The advantages of using a thicknesser with helical spiral cutterheads. So, the advantages of using a spiral head cutter as opposed to a standard ...

Learn why precision CNC Swiss machining is used in the production of medical electrodes made from MP35N® for electrical signal delivery devices.

Eddy current testing is an important method of nondestructive testing that is often used to inspect for flaws in the surface or sub-surface of metal materials.

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While CNC machining can produce an array of complex, precision metal components, there are some challenges to the process you need to be aware of.

It is a characteristic that is generally called out when you have a part that must rotate around a central axis and have all points on the entire surface of the part be in spec. In GD&T, the total runout symbol is a double arrow.

Pull rings for medical devices can be cut from 304 grade stainless steel tube or Swiss machined to provide specialty features and use other materials.

For example, having a perfect spindle won’t erase the effects of a wobbly collet, and a bad drill can ruin the perfection of the most perfect machine tool. So inherently, you are likely to have a TIR that exceeds what is called out due to the cumulative effects of the tools’ TIR plus the runout TIR.

You can measure runout by spinning the part while an indicator gage takes readings across the pertinent surface — either a cross section to measure circular runout or the entire part surface when measuring total runout.

Wire EDM cutting advantages and disadvantages for 2-axis cutoff depend on factors including the material used, part parameters, and surface finish requirements.

Custom bushings that are Swiss machined for use in catheters and other medical devices allow the devices to function at a high RPM while resisting wear.

Learn how the guide bushing and other features of modern CNC Swiss screw machines eliminate deflection to improve efficiency, consistency, and accuracy.

When a single part has multiple tolerances that conflict, the tighter, more challenging tolerance must guide production and ultimately drives the part’s cost.

Follow these tips on how to choose a vendor for cut off metal parts and get the results you want for your precision manufacturing needs.

The properties of tungsten wire are valued in the medical device industry, for use in electrocautery, electrosurgery, neural probes, and other applications.

Learn about the advantages of precision CNC machining in the manufacture of small, complex parts requiring tight tolerances, smooth finishes, and repeatability.

Along with the runout symbol, a diagram will typically show the circular runout tolerance zone — a two-dimensional area into which all points on the feature’s surface must fall.

It helps to have a partner like Metal Cutting, where our goal is to work with you to deliver high-quality precision parts that meet your specifications, while also keeping your production costs within budget.

If the TIR in a drawing is lower than our machine specs, as well as the TIR of any tools or accessories we would use, we know to alert the customer and decide the best course of action for moving forward.

Learn how to prevent and detect surface flaws in the glass to metal seals used in the manufacture of a wide range of electronic products.

People often ask Metal Cutting Corporation if we do “metal fabrication” — and the truth is, the answer depends on how you define the term.

Precision metal grinding is often the best way to remove small amounts of material and achieve the right finish or tight tolerance dimensions on part surfaces.

Learn how to optimize for manufacturability through a unified approach to product design and the creation of a thorough and detailed request for quote (RFQ).

In comparing common tungsten uses in 2007 and today, it is clear that tungsten remains one of the most widely used and beneficial of the refractory metals.

Countersink Drill Bit

While honing and lapping are both used to fine-tune the finish and dimensions of metal parts, the two processes differ in where and how they achieve results.

Tungsten wire continues to be a product that has a large number of diverse applications, for many of which there is no known substitute. Find out why tungsten remains widely used.

Circularity tolerance based on diameter helps to control roundness and ensure that small precision metal parts fit properly, move smoothly, and wear evenly.

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In the world of small metal parts manufacturing, the Geometric Dimensioning and Tolerancing (GD&T) system uses a combination of symbols and GD&T tolerances to provide insights into how to produce the features that are essential to a part’s form and function.

The total runout tolerance zone is a three-dimensional, cylindrical area surrounding the reference point, into which all points on the rotating part must fall.

Variance in worst case and RSS increasingly stack up as components are assembled. As shown in Figure 3 tolerance of assembly is always assumed to be larger than ...

When choosing a resistance welding electrode for any application, a thorough understanding of material properties helps to avoid production line issues.

Therefore, the fundamental concept is the TIR value of a part cannot exceed the cumulative TIR of all the tools used to make that part. What’s more, the TIR values of the tools are additive; one won’t cancel out another, and all can add to or worsen the wobble.

Countersinkingimplant

Metal Cutting Corporation uses visual and mechanical methods of metal inspection to help ensure that small parts meet customers’ manufacturing requirements.

Celebrating 50 Years of Precision Manufacturing: Metal Cutting Corporation is genuinely thrilled to say we have just passed a significant milestone in our company history.

Precision CNC Swiss machining is often used to produce bone screws and anchors with the features needed for a wide range of orthopedic and dental applications.

Wilson Tool countersinking tool punches a countersink without the need for a secondary operation. Countersinking is done quickly and precisely in one stroke of the punch.

With these RFQ tips, you can not only speed up the quote process, but also ensure you get the part you want and a cost estimate that is as accurate as possible.

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While the most familiar use of tungsten (incandescent light bulbs) continues to fade, the unique range of properties continue to make tungsten wire irreplaceable for a number of products and applications.

Learn why a small diameter metal probe requires choosing a material that is strong enough to maintain the probe’s shape, straightness, and direction.

The centerless grinding process is ideal for finishing small cylindrical metal parts that require a tight tolerance and high-volume production. Learn some of the fundamentals of this process.

The creation of new specialty metals offers alternatives to stainless steel for components used in medical device applications.

Learn how potting can be used to create a tightly sealed package for electronic switching devices, such as the flat ribbon in semiconductors.

A statistically valid sampling plan in quality control provides a high level of confidence that if the sample is acceptable, the entire lot is acceptable.

Beyond just machine make and model, there are a few things to know about your application to ensure you’re ordering the exact tooling you need. Use this Coining Tool template to assist you in ordering the right tool the first time. As always, our engineers are here to provide assistance at any phase of your project.

When measuring the perpendicularity of small metal parts, consider the effects of a part’s diameter, length, straightness, and manufacturing method.

Total runout, on the other hand, is used to control variation in all the points on the surface of a rotated part with regard to the part’s rotation on its axis.

Proper electrode design and construction is essential to ensuring consistent weld quality, minimum electrode sticking, and maximum electrode life. Learn how electrode design can impact your prod line.

As important as inspections are, 100% inspection requires time and cost without a guarantee of 100% compliance. See what a sampling plan is and how it solves this challenge.

For measuring and inspecting the ID of small parts tubing, pin gages or optical measurement systems help ensure that small tubing will meet specifications.

To avoid the challenges of verifying OD/ID concentricity, try to use other applicable GD&T symbols in place of concentricity in tubing drawings and designs.