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Jim Grimes, product manager of machine investments for Sandvik Coromant, points out that it’s not just important what tool you choose. It’s also important when you choose that tool. The best time to consider high-performance tooling is at the very beginning of the analysis related to any new part or new job. What tooling you will use for this job should be just as fundamental a question as what machine will you use.

Certainly you would never commit to tooling without choosing a machine. That would be absurd. For certain parts, it may not be clear at the outset whether a machining center or a lathe is the right choice, so obviously purchasing tooling at that point would be premature.

But shops make the opposite mistake all the time. They buy the machine tool first, then add tooling as an afterthought. This is almost as risky as buying the tooling without knowing the machine, because by the time the machine is bought, the shop may have locked itself into machine specifications and features that make it impossible to use productive tooling to its fullest advantage.

In other words, by not considering the cutting tools and the machine tool at the same time, the shop may rob itself of much of the savings it might have realized. In fact, the shop may even spend far too much on the machine tool, because the right tooling might have enabled the shop to get away with a lighter-duty or less expensive machine.

Here are just a few of the more specific reasons why cutting tools should be considered from the start:

Parameter Optimization

Knowing in advance what tools you will use to run a new part or a new family of parts will make it clear what spindle speed, feed rate, power and torque will be ideal for each one of those tools.

Equipped with this range, the shop can choose a machine tool that provides precisely those parameters.

Even better, the shop that identifies its needs this early may discover that only one tool requires the torque or power. That is, the shop may discover it can compromise on just one tool in order to get away with a significantly less powerful, less expensive machine.

Machine Features

Certain machine features are essential for taking advantage of some types of high-performance tooling. For example, some sophisticated tooling for turn-mill machines requires a positionable B-axis. The shop would not want to have to install this technology on the machine later.

An even better example is Sandvik Coromant’s CoroTurn HP tooling, which uses a focused stream of coolant to lift the chip away from the cut for faster speed and longer tool life. If the machine tool is not equipped with high-pressure coolant, then this benefit of CoroTurn HP cannot be realized.

Combining Tool Positions

Modular tooling can allow different milling and drilling tips to be quickly exchanged on a single tool body, potentially without having to re-measure the tool each time. If the shop knows that it is going to rely on modular tooling in this way, then it can specify a machining center with fewer positions in the tool magazine. Most of the tool positions can then be occupied by just the tools the machine will use all the time, while several modular tool bodies can accommodate all of the other cutting tool choices Thread Cutting Insert that the shop will use only occasionally.

Combining Operations

Some shops can even be too quick to assume that they need an extra machine.

A deep, critical bore can be an example of a feature that might seem to merit separate processing. The shop may assume it needs a rigid boring machine just for this feature, based on the guess that the lathe or machining center that does the rest of the machining will not provide a stable setup for this work.

But what about damped tooling? Sandvik Coromant has developed boring bars with internal damping technology that can counteract the vibrations on less rigid machines.

Not every shop is aware of technology innovations such as these, but they exist, and a knowledgeable tool supplier should know exactly when to apply them.

To repeat, engage CNMG Insert the cutting tool supplier early on! Machine tool technology is advancing, but cutting tool technology is advancing even faster. The example of the damped tooling , along with the diamond tooling of Rule #3 and the machine capacity savings of Rule #1 (see www.mmsonline.com/articles/the-new-rules-of-cutting-tools), all offer variations on the same promise. That is: The new machine you are considering buying might be able to do more than you think. Leverage today’s advanced tooling to make the very best use of your new—or existing—machine.

WTO’s QuickFlex quick-change system for driven toolholders Cermet Inserts is said to lower tooling costs, reduce tool-change time and increase flexibility. Comprised of an ER collet chuck and quick-change system within one toolholder, the system is designed for use with turning centers using bolt-on turrets. It is said to be well-suited for the multiple setups and frequent change-overs required for short-run manufacturing.

Available in a straight (radial) or right-angle (axial) configuration, the base unit enables tools to be clamped directly into the ER collet of the toolholder. Combined with a range of available adaptors, the system can accommodate virtually any machining process requirement, the company says. Cutting tools can be preset while the machine is operating to reduce setup time for tool changes at the machine. Changing tools is said to be quick and easy with the company’s one-hand wrench for tightening Cutting Tool Carbide Inserts the QuickFlex spindle and adapters. According to the company, the flexible system provides improved rigidity, performance and accuracy.

Methods Machine Tools Inc., a leading suppliers of machine tools and automation equipment in North America, recently added the FANUC RoboCut α-CiC series to its line of wire electrical discharge machining (EDM) products.

“The α-CiC series continues to push the boundaries of speed, precision, and reliability,” said Steve Raucci, Methods’ technical Carbide Grooving Inserts sales director and RoboCut product manager. “The redesigned α-CiC series creates a faster, more exact EDM experience.”

This generation of the RoboCut is designed for ultimate rigidity. The EDM machines minimize the amount of distortion embedded into each part, according to Methods. New discharge devices, powered by the SF3 power supply, are designed to improve surface roughening capabilities while maintaining high cutting speeds.

According to Methods, additional features include a taper adjustment function for high-precision taper cutting, thermal displacement compensation for increased stability and faster cycle times thanks to the automatic wire feeding system, AWF3, and core stitch technology.

Currently available in two sizes, the RoboCut α-C400iC has travel lengths Machining Carbide Inserts of 15.748" (400 mm) on the X-axis, 11.811" (300 mm) on the Y-axis and 10.039" (255 mm) on the Z-axis. Travel on the α-C600iC is 23.622" (600 mm), 15.748" (400 mm), and 12.204" (310 mm) on the X-, Y- and Z-axis, respectively. The new models will replace their respective counterparts in the α-CiB series. The C800iB, which belongs to the previous generation of RoboCut, the α-CiB, is still a part of Methods’ product offering.

Tungaloy has added 1.2 mm-wide (.047″-wide) DGS-style grooving inserts to its TungCut multifunctional grooving system.

According to Tungaloy, job shops that are mass-producing small parts with Swiss lathes can save costs by minimizing material waste in the part-off process. New 1.2 mm-wide (.047″-wide) grooving inserts can reduce the material waste produced by parting-off by up to 40% when compared with using 2.0 mm-wide (.079″-wide) deep hole drilling inserts insert. Tungaloy says this translates to, after 2,500 cuts, the saving of a 2,000 mm-long (78.74″ long) bar stock.

The new grooving inserts feature a DGS-style chipbreaker that generates smooth cutting and excellent chip evacuation. In combination with versatile AH725 grade, the insert reportedly ensures stable parting-off performances in a range of material groups.

The toolholders, which are designed for use on Swiss machines, are available in 10 × 10, 12 × 12, or 16 × 16 mm shanks. The insert is securely clamped in the seat by operating the screw located on the side of the holder, enabling the insert to be changed while the toolholder is still in the machine. This enables cemented carbide inserts insert change time to be reduced to one third of the time conventional Swiss toolholders would require, significantly shortening machine downtime.

In addition, toolholders designed for the machines with the sub-spindle are also available, aside from standard style toolholders. Tungaloy says this ensures stable operation when parting off a short workpiece close to the chuck.

K&H Industries has a long history of success as a tool and die shop and production metal stamper. In fact, the company has maintained steady production since the turn of the 20th century. Why would this company, which seemed to be running Carbide Aluminum Inserts just as it should, invest in a CNC machining center and draw manpower away from high-production stamping?

The answer to that question is twofold. First, machining capability streamlines tool and die production. Second, the new machining capability attracts new business from customers seeking critical, one-off parts.

Founded in 1905, K&H Industries differentiated itself by inventing new applications for stamping that solved practical problems. Examples include corner structures that made wooden milk crates stronger and easier to assemble, as well as electrical connections that are still in production today.

By the time Tom Sharkey purchased the company in 1997, it was still producing millions of parts per year. However, the new owner and his son, business manager David Sharkey, were not content to lean on previous Shoulder Milling Inserts success. More than twenty years later, David runs the shop floor with newfound efficiency, an achievement he credits to new processes and new technologies. When the opportunity arose to purchase a CNC machine tool, a Haas TM-2P, at auction in 2019, he saw the addition as a logical next step. 

On any given day, keeping stamping lines running might require everything from producing new parts to reproducing old parts to troubleshooting failed parts. Before, machining needs were split between in-house manual mills and a local EDM shop. The manual mills were so tedious, he recalls, that sending parts to the EDM shop was often faster, even if those parts didn’t require the precision of an EDM. With a CNC, David says he spends less time standing in front of the mill monitoring every pass. He can devote more attention to tasks like tending alarms, replacing stock on a stamping machine, shipping orders or communicating with customers.

As an example, he cites punches, which are common wear parts in stamping tooling. Featuring various angles and tapers, these parts require several tool changes. The CNC machine’s toolchanger performs this task automatically. Additionally, the part program can be re-used when the punch breaks again, rather than trying to recall the most efficient cutting strategies while also managing the shop.

Now, David says CNC has become a centerpiece of the shop’s productivity. Tom and David have settled into a rhythm where the initial design and customer consultation is completed by Tom in the front office, and then the part is programmed by David in BobCAD-CAM. The only parts that are still sent out to the EDM shop require tolerances tighter than +/- 0.001", such as die blocks and parts that interface with mating pins. 

Learning to use the CNC required David to spend months working through online tutorials and watching every video lesson he could, particularly Haas’s “Tip of the Day” series on YouTube. It wasn’t long before he wanted more, but not just for creature comforts. With a larger tool changer, a higher-capacity coolant system and a faster spindle for machining aluminum, the new Okuma Genos M560-V also helps with expanding business into one-off part replacements and emergency work for regular customers. 

In fact, the shop’s sole CNC machining center processes more emergency and one-off work for customers than in-house tooling, David says. Many of these customers do not have access to a CNC to make replacement parts for their own production lines, so providing this service helps build rapport. 

This is by design. The Sharkeys never run the machine at maximum capacity to ensure that it can handle rush orders without compromising other project timelines. This requires focusing on simple, competitive parts, David says, noting that the “sweet spot” includes those no larger than 4" x 10" x 24". 

As if to illustrate the point, one customer called while I was interviewing the Sharkeys, asking if a replacement part for a downed production line could be delivered the next day. David was happy to report that it would not be a problem. Running at full capacity may be the status quo somewhere else, but for the Sharkeys, keeping the machine open helps keep customers’ options open, too. 

The saying “too many cooks spoil the broth” isn’t something that only applies to the culinary arts. It can also relate to manufacturing operations. At its Fountain Inn, South Carolina, plant, Bosch Rexroth was using multiple software suites for tool management, in turn causing communication challenges. By investing in the Tool Management Carbide Turning Inserts System (TMS) from Zoller (Ann Arbor, Michigan), the company was able to streamline its tool management system to a single suite to reduce quality issues and improve efficiency.

At its Fountain Inn plant, Bosch Rexroth produces many different axial piston hydraulic pumps and valve housings for its drive products used in heavy equipment and agricultural applications. The plant has two production buildings with more than 90 CNC machine tools—mostly DMG and Mori Seiki machining centers—operating 24/7. Iron and steel materials are received from foundry suppliers and machined on the four- and five-axis machining centers, which feature large tool storage capacities.

Due to the complex design of the products Bosch Rexroth manufactures, the machining centers make use of an expansive cutting tool inventory, which comprises mostly special designs that produce multiple diameters and other complex part features. These tools must be available immediately when needed. Also, it is essential for the company to keep accurate, timely track of engineering changes, item availability, tool regrinds over the tool inventory and other indirect materials used on the production floor.

Bosch Rexroth already had Zoller tool presetters in the plants to provide accurate tool offsets and avoid crashes and other manufacturing problems. However, the company was also using another software to run its engineering tool management. The Zoller software reported on the reality of the tools while the engineering software provided direction on how to make the tool. This was problematic because the toolsetter operators worked with one system and the engineers worked with another. It became a challenge to make sure they could communicate with each other.

The company’s Technical Functions (TEF) department decided it was necessary to streamline the tool management system to minimize tool and process cost, improve throughput and ensure consistently high part quality. Looking at all the Carbide Turning Inserts options, Bosch Rexroth decided to invest in the Zoller TMS, reducing what had been three software suites—design, inventory and measuring—to a single suite. Now, just one software manages the engineering, toolsetting and tool management, and only a single set of data is available to operators, tool setters and engineers. The Zoller TMS Silver package is a single suite of software that is designed to combine effective warehouse management and standardized production data management with organized tool management.

All information is managed by the single Zoller TMS database, yet tools can be managed from the office, CNC machines, Zoller Tool Organizers, vending machines and directly from the presetting and measuring machine. Since the system is modular, its functionality can be extended step by step going forward. Right now, Bosch Rexroth takes advantage of stored tool data and DIN4000 article characteristic information to optimize inventory cost control as well as tool production.

For the TEF department, the tool storage management module has been particularly useful, because it enables managing complete tool assemblies and components while keeping accessory inventories up to date. The storage location management in the warehouse includes a 3D design kit that enables current stock to be displayed three-dimensionally and items to be assigned to a virtual bin location. The database provides an overview of each item’s location, where it is in circulation, and the balance on hand in stores.

Feedback on circulation and stock levels are available at the push of a button. This is a major asset for increasing manufacturing transparency, which helps Bosch Rexroth run production economically around the clock when needed. The simple import and export of tool usage data also helps ensure quality and integration of various machines and departments.

There is no longer redundant data storage in multiple locations around the two production buildings—if an engineer makes a change to the tool design, it is visible to everyone. Previously, when the engineer made an update, that person would have to tell the tool setter to update his or her record as well, which took time and inevitably included some inaccuracy, says Dave Morley, Zoller product manager.

The company has started measuring every tool feature and adding tolerance information to the database, he says. Using the complete record, the engineer can now see the history of the tool’s setup measurement results. For example, the engineer can now know if the tool tolerance has been in the mid-range most of the time or if it has ever approached the limits. Without the complete record, this information would have been unavailable, making it difficult to meaningfully improve the tool design or features, Mr. Morley says.

Since engineers can now access the statistical measurement results for each tool assembly at a desk or the machine tool, they can make timely corrections or improvements to the tool design, which improves machining capacity, cycle times and part quality. It also helps identify and address the root cause of machining quality issues.

Bosch Rexroth has strict rules that a tool cannot be passed to manufacturing if it is out of tolerance; however, this has become less of an issue since engineers can now investigate any tool issues and look for a solution before cutting even starts. So far, tool breakage at Bosch Rexroth has been curbed from an average of 15 to fewer than eight tools per 1,000 parts produced.

The TEF department also wanted to better understand how the tools are used in the machines. The engineer can search the tool information through the TMS at a desk or at the presetters to make the connection between how the tool is set and how it performs. In terms of performance, this information is collected as the operator scans his or her badge, scans the machine identity and inputs the reason code for the tool change. It is now transparent which tools are changed the most and for what reasons.

The tool assembly history provided by the TMS is used to help optimize and control tool component inventory. Another way the tool management software controls inventory is through access to vending machines. At vending machines, users can look up the bill of material for any tool assembly and be accurately guided to the required components.

To keep designed tools organized, Bosch Rexroth uses the Zoller Tool Organizer to know the exact location of each and every tool or component. Flashing LEDs clearly indicate location of needed items, providing a fail-safe check-out system. Also, the Tool Organizer is interfaced directly to Zoller stock management.

As a result of Zoller’s TMS, the Bosch Rexroth plant has seen a reduction in quality issues and an increase in production efficiency. The TMS has also eliminated centers of “tribal knowledge,” meaning information no longer resides with just one or two people. Engineers are truly in charge of the tool. 

The DSI machine project is the latest in an extensive series of retrofits at Major Tool & Machine. Here, Scott Elder of Indiana Automation installs wiring at the electrical enclosure of one of the previously upgraded machines, a Cincinnati U5.  

Major Tool & Machine (MTM) is no stranger to extensive retrofit projects, and the company’s latest order is no exception. Set for completion in 2015, the job involves equipping a DSI (Dorries Scharmann) turn-mill gantry machine with not only a new Siemens CNC and drive system, but also a new cross-saddle, ram, and five interchangeable cutting heads, among other components. This work follows close on the heels of a series of similar projects that the shop began to CCMT Insert undertake in 2010, and it can be similarly informative for manufacturers considering their own rebuilds.

As detailed in this article from our May issue, these previous projects demonstrate that retrofits provide the opportunity to not just restore machines to like-new condition, but also to add new capabilities. Just as importantly, the article describes why rebuilding MTM’s old machines would have been a complicated, involved process even if the company had less lofty goals. In fact, anything less than a total motion system upgrade wouldn’t even have been an option.

The DSI machine rebuild also demonstrates the need to plan around downtime. The project is part of a multi-million dollar order from MAG IAS that also includes two new machine tools: A VTC 2500 and a U5 XL 2500 universal portal mill with turning capabilities. The rail-type U5 XL 2500, the newest and largest model of the U5 portal mill series, will initially replace production capacity during the rebuild the DSI machine.“This is an extremely complex project that involves much more than simply adding machine tools, because it is critical that we maintain our large-part mill/turn capacity when the DSI machine goes offline,” says Steve Weyreter, chairman and CEO of MTM. “Part of our reputation is based on the depth of our capacity, so coordination and timing are vital when we take a critical machine offline.”

Here BTA deep hole drilling inserts are more specific details on the new machines and what the DSI machine retrofit project will entail.

Having the right cutting insert is essential for achieving optimal tool life in any machining process. A cutting insert is a tool that is used to cut material in a specific manner. The right insert selection can ensure that the tool is able to withstand the cutting forces and maintain its properties for a longer period of time. This, in turn, can result in more efficient and cost-effective machining operations.

The selection of the right cutting insert involves careful consideration of several factors. This includes the material being machined, the cutting environment, and the application. The cutting insert should be strong and wear-resistant enough to withstand the cutting forces, and it should also provide an adequate cutting edge to ensure that the material is cut cleanly and precisely. Additionally, the cutting insert should be designed to minimize heat buildup, as this can Carbide Grooving Inserts lead to premature tool failure.

When selecting a cutting insert, it is important to consider the cutting conditions. This includes the cutting speed, feed rate, and depth of cut. The cutting speed should be appropriate for the material being machined, and the feed rate and depth of cut should be adjusted to ensure that the insert can cut efficiently and accurately. Additionally, the cutting insert should be selected based on the type of machining operation, as some inserts may work better for certain operations than others.

The selection of the right cutting insert can have a significant impact on the longevity of the tool. By selecting the right insert, the tool will be able to withstand the cutting forces for a longer period of time and maintain its properties. This can result in improved efficiency, reduced costs, and Carbide Threading Inserts improved quality of the machined parts. Therefore, it is essential to select the right cutting insert for achieving optimal tool life.

Cutting insert coatings have become an integral part of the manufacturing industry in recent years. The coatings allow for improved performance and efficiency in various machining operations. As technology advances, so too do the advancements in cutting insert coatings. In this article, we will discuss the latest advancements in cutting insert coatings for improved performance.

One of the most recent developments in cutting insert coatings is the use of nanotechnology. This type of coating offers a higher level of wear resistance, higher hardness, and improved lubricity. This type of coating also allows for increased machining speed and improved surface finish. Additionally, nanotechnology can provide improved corrosion resistance and improved thermal stability, making them very beneficial in a variety of different applications.

Another advancement in cutting insert coatings is the use of diamond-like carbon (DLC) coatings.turning inserts for aluminum This type of coating offers a very high level of wear resistance and hardness. Additionally, they are extremely hard and have excellent lubricity, making them ideal for high-temperature applications. This type of coating is also highly resistant to corrosion and thermal shock, making them ideal for machining operations in harsh environments.

Finally, plasma enhanced chemical vapor deposition (PECVD) coatings are becoming increasingly popular. This type of coating is created by depositing a metallic film on the cutting insert. This process provides a very strong and durable coating that is highly wear-resistant. Additionally, it offers a very low coefficient of friction and improved thermal stability, making it ideal for a variety of machining operations.

Overall, the advancements in cutting insert coatings have greatly DNMG Insert improved the performance and efficiency of machining operations. Technology has allowed for coatings that offer increased wear resistance, improved lubricity, and improved thermal stability. Additionally, these coatings are highly corrosion resistant and have a low coefficient of friction. As technology continues to advance, more advancements in cutting insert coatings are sure to come.

Cermet is a composite material composed of ceramic and metal materials, which has excellent wear resistance and cutting performance. Cermet inserts are a type of cutting tool material used for machining heat-resistant alloys. The hardness of heat-resistant alloys is higher than that of ordinary steel, and the cutting performance of cermet inserts is VCMT Insert better than that of other materials. Therefore, they are widely used in the machining of heat-resistant alloys.

Cermet inserts are made of a combination of ceramic and metal materials, which gives them excellent wear resistance and cutting performance. They are suitable for machining high-temperature alloys with a hardness of up to HRC60. Cermet inserts are also ideal for cutting high-temperature alloys with high cutting resistance. Their excellent abrasion resistance also makes them suitable for machining soft, heat-resistant alloys.

Cermet inserts are designed for high-speed and high-precision machining. They provide excellent surface finish and high accuracy, which is especially suitable for high-precision parts. They also have a long service life, which makes them a cost-effective solution for machining heat-resistant WCMT Insert alloys.

In summary, cermet inserts are an excellent choice for machining heat-resistant alloys. They have excellent wear resistance and cutting performance, which makes them ideal for high-temperature alloys with a hardness of up to HRC60. They also provide excellent surface finish and high accuracy, which makes them suitable for high-precision parts. In addition, they have a long service life, which makes them a cost-effective solution for machining heat-resistant alloys.