Marubeni Citizen-Cincom’s tooling and accessory workshop at IMTS 2024 offered a chance to learn more about ancillary devices that can boost machining efficiency and capability.

At EMO 2023 in Hannover, Germany, FANUC presented an automated manufacturing cell simulating the complete production and measurement of aluminum electric vehicle (EV) inverter cases.

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Production Machining’s October 2024 technology showcase includes some of the latest technology from Ceratizit, Kennametal, Mate Precision Techologies, Horn and Mazak.

PMTS 2023: The InchMax Series includes 2- and 4-flute square end mills which feature Union Tools’ UT coating and its standard Super Micro Grain carbide and tolerances.

“When I visit a shop that is looking to transition to micromachining from more traditional operations, especially drilling above 0.10-inch diameter, there are a series of questions I pose to help them understand how different the process considerations for micromachining are from most other metalworking operations they have dealt with,” says Burley. “Some of these are obvious, but others are more subtle.”

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Because of the large number of holes and to save cycle time, the drilling operations are performed without center drilling or peck drilling routines.

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Precision Machined Products Association's mission is to progressively lead  members to sustainable success with reliable and relevant information, resources, advocacy, and networking opportunities. More information for the conference to come.

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This 2023 Emerging Leader developed a product in response to a call for help from Yamaha that was a huge hit in the snowmobile industry when it hit the market in 2010. In fact, it is now a common product that most snowmobile OEMs have implemented.

High precision collets, made to class AA standards, provide stable runout and afford easy tool changes. Cleaning the collet during tool changes helps maintain repeatability.

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Production Machining’s September 2024 technology showcase includes some of the latest technology from Expand Machinery, Paperless Parts, Monaghan Tooling Group, Walter USA and more.

Various methodologies paired with online tools can help small to mid-sized manufacturers determine how to predict and calculate the potential economic benefits of robotic equipment for their specific needs.

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Recent testing has shown that thread rolling can be more economical than thread cutting when producing 4,000 parts or more. A newly created calculator can help you to determine which might be the better option for your threading applications.

“A class of specialized machines has been developed specifically to perform micromachining operations,” Burley explains. “For shops planning to micromachine on existing equipment, I recommend having the machine allocated for the work evaluated by a specialist to make sure it is capable of sufficiently fine feeds and has dynamic runout well below 0.0001-inch TIR.”

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First, let’s try to define micro-drilling. Like so much metalworking vocabulary, hard and fast definitions are often elusive. However, Jack Burley, president/COO at Big Daishowa, a distributor for Swiss micro-drill maker Sphinx’s product line, defines micro-drilling with a number. Burley says Sphinx defines micro-drilling with a starting diameter of 0.05 mm (0.002 inch) and ranging to 2.5 mm (0.10 inch). For the purposes of this article, let’s agree with this definition. He also adds that this benchmark is a moving target, as improvements in production technology and materials used to make these tiny tools continue to push for a smaller minimum starting diameter.

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User-friendly inspection software for CNC machining centers was shown at IMTS 2024 monitoring measurements between and after machining while performing SPC based on recorded measurement values.

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Another technique to micro-drill on an angle requires a machine with a B-axis swivel spindle. First, the spindle feeds the drill point perpendicular to the entry point of a workpiece. Once the drill makes contact with the work, the B axis swivels to the angle spec and drills the hole. Using this method, only one tool is needed.

“We successfully micro drill holes with 10 to 1 and as much as 15 to 1 length-to-diameter ratios,” Mr. Burley says. “In addition to using a center hole to guide the drill, we recommend a pecking routine. For hole depths two times the diameter, I call for a bump, bump, bump, retract routine. With each additional two times the diameter, I add an extra bump and full tool retraction. A machine tool with fine servo control is critical in this operation.

Production Machining’s June 2024 technology showcase includes some of the latest technology from Siemens, Ceratizit, Walter, Kennametal and more.

Production Machining’s October 2024 technology showcase includes some of the latest technology from Ceratizit, Kennametal, Mate Precision Techologies, Horn and Mazak.

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 – everything you need to take back and immediately put to use in your own shop. __PRESENT

Ideally, a micro-drill is best applied when it can be fed perpendicular to the workpiece. However, not every hole has the luxury of perpendicularity. There are angles.

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This new vertical turning center with measurement and robotic automation processes is able to produce vehicle ball joint ball pins in 7 seconds.

SolidCAM aims to align its product development and customer engagement strategies to address the evolving needs and challenges of the manufacturing industry.

Micro-drilled hole tolerances are tightening up for some applications. Micro-boring and reaming tools are available for finishing drilled holes. The boring bar shown here is 0.025-inch diameter with a 1-micron adjustment on the holder and a 7-mm shank.

“Accuracy of the drill is very critical in micro-drilling,” Mr. Burley says. “You had better be on size because the operation is basically a ‘one shot deal.’ To cover the size range needed, we offer micro-drills, drills and center drills in 0.01-mm (0.0004-inch) increments.”

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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

The next question Burley wants to know from a prospective micro-drilling shop is how many holes are needed in the workpiece. Micro-drilling can be used effectively in volume production both in workpiece quantities and number of holes per part. (see “Try This on for Size” at the bottom of this page.)

According to Burley, if the entry point on the part that’s planned to drill is less than 10 degrees, careful feeding of the drill can accomplish the operation without the drill walking across the angular surface. Beyond 10 degrees, micro-drills need help getting a purchase on the workpiece. Shops can get around this problem by milling a small notch on the entry angle, effectively creating a perpendicular starting point for the center drill followed by the drill.

These spindles available on Tschudin CNC centerless grinders are designed to minimize the heat transfer factor while optimizing dimensional stability and material removal rate.

“The number of holes needed to be drilled can change the recommendation and specifications of the micro-drilling process,” Burley says. “If the job calls for many holes, I try to optimize the process for maximum efficiency and tool life. For example, I would try to eliminate center drilling if possible to speed production. To do this, a coated tool can be used because of its reduced tool wear. Generally, micro-tools are not coated because of geometry. The thickness of a PVD coating can influence the nominal size of a micro-tool. For volume production, any coating used on the tool must be ultra thin (less than 0.001 mm) and very smooth.”

Toolholding technology for wire or standard shank drills is as important to the micro-drilling operation as the machine tool. The maximum runout for micro-tools with drill diameters less than 2 mm (0.080 inch) is 0.0025-mm (0.0001-inch) TIR measured at four times the diameter.

Micro-drills are intolerant of runout. The small tool size accentuates any runout in the machine spindle, toolholder and collet.

Cutting tools play a key role in machining tiny screws on Swiss-type lathes for this Switzerland-based watch manufacturer.

“The skills are learnable,” Burley says. “I’ve seen micromachinists who know when a cutter is about to fail or when it is going dull. They can’t tell you why; they just know. It’s a spooky, but valuable skill. In my experience, shop owners must commit to training operators in the specific skills needed in micromachining in addition to investing in the process hardware. Cutting with tools smaller than 0.100 inch is a different animal.”

Recent testing has shown that thread rolling can be more economical than thread cutting when producing 4,000 parts or more. A newly created calculator can help you to determine which might be the better option for your threading applications.

These spindles available on Tschudin CNC centerless grinders are designed to minimize the heat transfer factor while optimizing dimensional stability and material removal rate.

Zeiss Quality Innovation Days brings together quality and metrology experts from all over the world to take part in industry-specific sessions.

Various methodologies paired with online tools can help small to mid-sized manufacturers determine how to predict and calculate the potential economic benefits of robotic equipment for their specific needs.

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

“Micro-tool makers can influence the performance of tools in different materials by varying the geometry of the drill and the material from which the tool is made,” Mr. Burley says. “Manipulating the web thickness of the drill point allows us to add or delete point strength based on the workpiece material. Although HSS is the most forgiving material, but nano-grain carbide gives the longest life. I recommend that the shop work with the tooling vendor to establish a starting point for cutting data and tool specs based on the job because each vendor makes tools a bit differently.”

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Production Machining’s September 2024 technology showcase includes some of the latest technology from Expand Machinery, Paperless Parts, Monaghan Tooling Group, Walter USA and more.

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Hurco’s TM8MYi slant-bed lathe comes equipped with a Renishaw swing-down tool setter and a bi-directional, servo-driven live tool.

Micromachining does not necessarily equate to miniature parts. While it’s true that many applications in medical and electronics manufacturing deal with miniaturization trends, many relatively large workpieces require ultra small features that can only be accomplished by micromachining techniques.

For many micro-drill applications, the ability to cut such a small hole is sufficient. However, as micro-drilling operations proliferate, there is increasing demand to hold these tiny holes to similar tolerances for size and surface finish as non-micro holes.

Various methodologies paired with online tools can help small to mid-sized manufacturers determine how to predict and calculate the potential economic benefits of robotic equipment for their specific needs.

Production of micro threads can be challenging, but using the most suitable tools for a given application can simplify the task.

Applications for micromachining continue to grow. Successful machining with small tools calls for a different set of process skills on the shop floor.

Can increasing productivity and reducing carbon emissions go hand-in-hand? For its high-volume machining customers, Sandvik Coromant offers a tool for data collection and comparison to aid sustainability-minded process decisions.

The round part (in the photo below) for the medical industry is called a filter. It features 400 micro-drilled holes, which are barely visible. For Jack Burley, vice president of Sphinx micro-tools line, this is what micro-drilling is about.

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“I’ve seen shops where 0.25-inch diameters are the norm, trying to implement 0.060-inch-diameter cutters by simply exchanging tools and scratching their heads when the operation doesn’t perform,” Burley says. “The problem is that when you break through the threshold of 0.10-inch diameter, the physics of machining get much more precise. Correspondingly, the approach to machining must tighten up as well. It’s not a simple substitution, but a disciplined shop can make it work well.”

“Tighter hole tolerances have led to the development of finishing tools,” Mr. Burley continues. “Micro boring and reaming tools are available to improve the typical 20-rms surface finish created with drilling and improve size and straightness well beyond what a drill alone can produce. Once the process basics for micro-drilling are in place, feed control, spindle and toolholder runout; cutter material and geometry; and cut data—micro boring and reaming to hold 0.0001-inch tolerances—become very doable.”

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

In the late 1800s, a new technology — Swiss-type machines — emerged to serve Switzerland’s growing watchmaking industry. Today, Swiss-machined parts are ubiquitous, and there’s a good reason for that: No other machining technology can produce tiny, complex components more efficiently or at higher quality.

The key to micro-drilling is the tool’s ability to produce even wear across all cutting edges in order to reduce the force required to evacuate chips and prevent chips from welding themselves to the flutes. Therefore, the surface finish on these drills must be ultra fine.

Deep hole drilling with micro-tools is improving as the tools and techniques improve. Center drills with a reverse-diameter tolerance (that is, +0.004 mm, -0) rather than the standard tolerance in the opposite (negative) direction provide a pilot hole for deep drilling operations. This operation allows the long and structurally weak drill to enter a slightly oversize hole to prevent binding and breakage.

PMTS 2023: The Mazak Syncrex series comes in four bar capacities, ranging from 20 to 38 mm, and is available in 7-, 8- and 9-axis configurations as well as a 9-axis model with full B-axis contouring.

We thank you for your continued interest in and support of PM and welcome any questions you might have about the brand’s new content gating strategy.

Join this webinar and discover how to overcome multi-channel mill-turn and Swiss CAM programming challenges using SolidCAM, with amazing machine simulation and customized post-processors tailored for your mill-turn and Swiss CNCs. Darrin Bryant, SolidCAM’s applications engineer, will highlight how to utilize SolidCAM's CAM software to enhance your CNC manufacturing and demonstrate how to optimally set up your projects for guaranteed success. Agenda: Major benefits of SolidCAM's single window integration and full associativity in Solidworks Embracing the future of increasingly complex CNC machines—including five-axis, Multi-Channel Mill-Turn and Swiss CNCs Exclusive features of SolidCAM's iMachining that provides much shorter cycle times and superior tool life Using iMachining Technology Wizard takes the guesswork out of defining cutting conditions and automatically provides optimal feeds and speeds while considering stock materials, cutting tools and CNC machine properties Using SolidCAM’s Toolkit to easily create customized precision project setups Highlighting the advantages of multiple verification options in SolidCAM Utilizing SolidCAM’s operations sequence manager to simplify synchronized part creation with fewer steps and higher success

Mike Medeiros, production manager at North Easton Machine Co., has been advocating CNC Swiss lathes for years, attempting to persuade his local high school’s administration to add the technology to the school’s machining program. Finally, his efforts paid off.

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A multispindle platform designed to combine the high production speed of a cam-driven machine with the precision and repeatability of CNC also includes technology to speed set ups for new jobs.

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As he progressed to CNC Swiss lead and later to his current position as CNC Swiss production supervisor, Darrin Baker helped the Swiss department at Liberty Precision double its productivity, according to his nominator.

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Starting on Thursday August 8, 2024, PM will begin “gating” its premium content, asking all new website users to provide some information about themselves — name, title, employer, email address — before they are provided free access to the content.

Probably as important as all of these questions is whether or not your people transition to micromachining. Handling cutting tools that are smaller than a human hair requires not only new machining process considerations, but understanding the need for gentle handling of these fragile cutters.

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The Production Machining media brand covers advanced new technology, practices and processes in the manufacture of precision machined parts in high volumes. About Us

Basically, micro-drills are made one of two ways: as a “wire” in which the shank diameter is the same as the drill diameter, and as a standard shank tooling, which uses a 1/8 -inch or 3-mm shank diameter regardless of the drill tip size. The wire drill has cost advantages because it’s less expensive to manufacture; however, it requires a range of collet sizes to accommodate different diameter drills. It is also more difficult to handle because of its smaller OD.

New part programming developments continue to be added to the Tri-County Technical College curriculum and solutions for Swiss-type lathes might soon be included.

Production Machining’s September 2024 technology showcase includes some of the latest technology from Expand Machinery, Paperless Parts, Monaghan Tooling Group, Walter USA and more.

Matching the material to be drilled to the cutting tool is similar to conventional drilling operations except that in micro-drilling, the cutting edges must be very sharp and dead on center. There simply isn’t the structural integrity in these tiny tools to “bull” their way through a workpiece.

Machine tools capable of performing multiple functions and machining parts to completion are becoming the standard rather than the exception. Incorporating automation into these systems allows for extended periods of operation without the need for operator intervention.

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High-speed spindle technology was key to effective milling of small cardiac monitoring components complete on a CNC sliding-headstock machine platform instead of running them across two mills.

“Because micro tools generate small chips, less heat from cutting is transferred to the chip. This routine is necessary to clear the chips and cool the drill. We recommend using mist oil/air for chip evacuation and cooling,” he adds.

The Precision Machining Technology Show is a great example of discovering ways shopfloor employees can become more efficient, thereby helping shops become more profitable.

Micromachining requires a machine tool that has high sensitivity and fine resolution in the feed axis. Machines must also have very precise spindles capable of high-speed rotation with low dynamic runout. Dynamic runout is the measurement of the spindle at speed. It is performed using laser or capacitance resistance technology.

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Here are some tips for choosing, maintaining and customizing a granite solution that will best meet your shop’s particular inspection needs.

Now representing six brands in North America, Platinum Tooling offers tooling and related accessories for a range of machine tool types, including CNC mills, lathes and Swiss-types.

I recently learned about a 153-year-old manufacturer that has produced billions upon billions of precision, metal pins which started another business making one-off wooden baseball bats. (Like I asked it to do for me and you’ll see at this year’s Precision Machining Technology Show). Here I explain why it’s worth the time to read that article.

Individual elements of the machining process such as machine tools, tooling and even CAD/CAM software play a role in overall machine shop sustainability. Observing the entire process especially when it comes to their influences on energy usage is key.

A multispindle platform designed to combine the high production speed of a cam-driven machine with the precision and repeatability of CNC also includes technology to speed set ups for new jobs.

Micro-milling can be a companion process to turning-based production machining. This article looks at some of the technologies that go into a micro-milling machine and why they are important to successful operation.

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“The toolholder and machine spindle form a system that must deliver the drill tip into the work as precisely as possible,” Burley says. “Our tests show that high precision collets, made to class AA standards, can provide stable runout and afford easy tool changes. For ultra-small diameters on a machining center, the collet is normally hand clamped directly into the spindle to eliminate positioning errors from the automatic toolchanger.”

Rotary transfer machines remain well-suited for high-volume production, but are now more accommodating to smaller batch sizes.

We asked Burley how he goes about qualifying a precision machined parts manufacturer looking to get into micro-drilling operations. He is quick to point out that applying this technology, as defined, takes a commitment from the shop that is different than most other operations the shop has implemented.

Superb critical thinking, top-notch leadership skills and a passion for building a strong team are a few of the common traits held by this year’s five Production Machining Emerging Leader award winners.

PMTS 2023: This tool management solution with Optik software is designed to help shops increase production output and decrease human error.