Indexable Mills Speed Cavity Cutting - ball nose insert milling cutter

 2024-08-17 18:44:21

In this webinar, industry-leading experts will demonstrate how additive manufacturing can revolutionize your operations and answer the question: Can you afford not to? From rapid prototyping to robust fixturing and specialized custom tooling, it’ll showcase the diverse applications that can drive your business forward in a time where cost and time saving can be crucial. Discover how to reduce costs, accelerate production cycles and achieve unparalleled design freedom through the strategic integration of 3D printing technology. Phillip’s panel of seasoned professionals will share real-world examples and practical insights to help you understand the potential of additive manufacturing. Learn how to overcome production challenges, improve product quality and gain a competitive advantage. It will explore the cost-benefit analysis of 3D printing — including material and labor savings — as well as the potential for increased revenue. Join this webinar to discover why additive manufacturing is no longer a luxury, but a necessity for success. Agenda: Prototyping example: quick-change prototype Custom tooling real-world example: press brake, tube bending die CMM fixturing and workholding example: CMM fixture and soft jaw

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

The 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.

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.

Horn USA’s new booth concept is designed to enable attendees to (literally) get a better feel for its various tooling offerings.

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

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

High-feed machining is a machining strategy that uses chip-thinning cutting tool geometry to enable exceptionally high feed rates, typically with a high lead angle and shallow depth of cut. Machinists using this strategy have been able to both increase productivity thanks to the higher metal-removal rate and increase tool life thanks to the constant chip load of high-feed toolpaths.

The DiFeedWinV, for example, is a 90-degree indexable end mill designed for the die/mold industry. Based on the existing DiPosFeed line, it is designed for milling in deep cavities, but Harpaz says the V-shape of the insert pocket provides even greater rigidity and enables even higher feed rates than the DiPosFeed line.

The New Product Rollout showcased dozens of new and updated cutting tools, with high-feed machining as one of the major highlights. According to Jacob Harpaz, the benefits of this advanced machining strategy will only increase its popularity with shops. Photo Credit: Ingersoll

Forget “additive versus subtractive.” Machining and metal additive manufacturing are interconnected, and enhance the possibilities for one another. Here is a look at just some of the ways additive and machining interrelate right now.

Standards for surface finishes and profiles are not static; they change as technology changes or new processes come along that need to be considered.

When revising part designs, investigate the 3D CAD, the 2D drawing and the part’s functional requirements to determine which details should be tightened up.

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

Weldon Solutions is demonstrating three grinders at IMTS 2024. Though they differ in size and use case, all feature the company’s hallmark customizations.

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.

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

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.

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

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.

Rob Guiao, Chris Hall and Bassanio Peters will demonstrate relatable situations to equip you with data to improve predictability, future-proof operations and maximize ROI. Agenda: Explore the importance of data in decision-making, especially for facility upgrades or new projects Learn how comprehensive solutions for manufacturing and construction projects can improve predictability and ROI See real demonstrations of machine integrations, facility layouts and automations to ensure proper throughput and integration

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."

Like the high-feed milling options, these barrel cutters lean into newer approaches to machining that promise to dramatically improve productivity. Clearly, Ingersoll hopes that its tooling combined with these machining strategies will enable shops to stay competitive in the modern metal manufacturing marketplace.

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

Formnext Chicago is an industrial additive manufacturing expo taking place April 8-10, 2025 at McCormick Place in Chicago, Illinois. Formnext Chicago is the second in a series of Formnext events in the U.S. being produced by Mesago Messe Frankfurt, AMT – The Association For Manufacturing Technology, and Gardner Business Media (our publisher).

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.

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

Babcock International Group (Babcock), the defence company, has been awarded a two-year contract extension by the UK Ministry of Defence (MOD) to continue to provide technical support services across the UK armed forces.

At its New Product Rollout, Ingersoll showcased a number of options for high-feed machining, demonstrating the strategy’s growing footprint in the industry.

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?

Tooling manufacturer, Horn has introduced a new carbide insert grade, SG66, for turning components from steel that has been case hardened to 58 HRC.

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

Walter USA has acquired PDQ Workholding, intending to strengthen its offering of workholding products and develop future cutting tool sales.

Zoller’s open house in Ann Arbor, Michigan, provided attendees with a glimpse of the connectivity and efficiency the company’s products offer to users.

There are no different grades of CBN. Differentiation between tools is down to the CBN volume fraction, the fillers, grain size and the ceramic/metallic binder phase (cobalt/nickel). This results in different CBN substrates. Hard machining is usually carried out without coolant, as these cutting materials have high heat resistance and the elevated temperature within the chip formation zone has a positive effect.

Grant funding for workforce training or the purchase of new equipment is an undervalued but complex resource for machine shops. We enlisted an expert to help navigate the process.

From quadruped robot dogs, to an in-booth putting green where you can test out a new golf putter, to a 3D-printed car and more, attendees enjoyed cutting-edge technology and innovations all week long. Take a look to see what (or who!) you might have missed this week!

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.

The choice between buying a new machine or refurbishing the current one will become clear after a thorough assessment of the machine.

Walter has now launched its new X·treme Evo Plus drill from the DC180 Supreme product family that is now available up to 8XD for the first time.

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.

Tool-holder-spindle-machine combinations each have a unique dynamic response in the same way that each person has a unique fingerprint, which can be revealed using modal testing.

Consistency is key for beryllium manufacturing, so the data visibility granted by Harmoni has swiftly become a vital, profitable tool in the shop’s arsenal.

At a recent event announcing its latest product lines, Ingersoll Cutting Tools made one thing clear: it sees high-feed machining as the future of metal manufacturing.

Pairing a shoulder mill with a five-axis machine has cut costs and cycle times for one of TTI Machine’s parts, enabling it to support a niche racing community.

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.

Working closely with customers and making careful investments has enabled this Wisconsin machine shop to tackle difficult jobs with tight deadlines as a core part of its business.

“Barrel finishing lets you finish with four times the step height,” Harpaz says, “saving 75% of passes.” He goes further: “I predict that the ballnose will disappear.”

During the New Product Rollout in Rockford, Illinois, Jacob Harpaz — chairman and CEO of IMC Group, the parent company of Ingersoll — discussed the importance of continuously developing new technology. “We must innovate with the purpose of increasing customer profitability,” he says. To illustrate this, he discussed a wide range of new and current cutting tools that reduce machining time, focusing especially on high-feed machining.

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.

Tool-holder-spindle-machine combinations each have a unique dynamic response in the same way that each person has a unique fingerprint, which can be revealed using modal testing.

FABTECH 2024 will be held October 15-17, 2024, in Orlando, Florida, at the Orange County Convention Center. FABTECH provides a convenient ‘one-stop shop’ venue where you can meet with world-class suppliers, discover innovative solutions, and find the tools to improve productivity and increase profits. There is no better opportunity to network, share knowledge and explore the latest technology, all here in one place. Future U.S. Show Dates and Locations 2025 – September 8-11 at McCormick Place in Chicago, IL 2026 – October 21-23 at Las Vegas Convention Center in Las Vegas, NV 2027 – September 13-16 at McCormick Place in Chicago, IL

Manufacturers continue to feel the pressure to reduce costs, increase efficiencies and meet their sustainability strategies. As the industry evolves to keep pace with these priorities, there are opportunities within metalworking processes to use less resources with advanced lubricants and technical expertise. Agenda: An overview of metalworking lubrication Evolutions in metalworking lubrication Experience on the shop floor Key takeaways

Harpaz discussed both solid-carbide barrel-style end mills and indexable milling tools that emulate the barrel-shaped profile, praising both for enabling shops to dramatically increase production speed over ballnose end mills. “We are in love with the barrel because the barrel is so fast,” he says.

The ultra-hard material is capable of smooth machining even during interrupted cutting when hard turning and grooving. By extending its existing standard ranges of Supermini 105, Mini 11P, 229 and 315 systems, Horn is able to deliver the CBN tools quickly from stock.

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

The Mill A Groove tool can be used to cut step grooves, convex and concave radius grooves, chamfered edges, angles and special profiles with a single insert.

Ingersoll seems to take this claim seriously, as it introduced multiple indexable barrel-shaped cutters to serve this niche:

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.

Ceratizit USA has promoted Troy Wilt from national sales manager to managing director of Ceratizit USA, cutting tools division.

The MarSurf CD 140 AF is designed to measure many different kinds of workpieces, making it suitable for a wide range of measurement tasks.

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.

Dillon Manufacturing’s extra-long hard jaws feature extended reach, making them well suited for machining small diameters.

According to Harpaz, 75% of the cost of making a part is fixed, with the largest variable cost being the time to machine the part. That makes reducing production time the most effective way to reduce the cost of a part, which guides Ingersoll’s cutting tool designs.

Incremental mode can be more advantageous when programming sculptured surfaces or for certain hole-machining canned cycle applications.

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.

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

The NeoMill-Alu-QBig indexable insert milling cutter from Mapal stands for top performance in high-volume milling of aluminium. The tool manufacturer thus offers a very economical solution for use on high-performance machines, such as those found primarily in the aerospace industry.

Horn has announced an expansion of its product portfolio to include tools tipped with cubic boron nitride (CBN) for machining difficult materials, such as superalloys and hardened steels. The ultra-hard material is capable of smooth machining even during interrupted cutting when hard turning and grooving. By extending its existing standard ranges of Supermini 105, Mini 11P, 229 and 315 systems, Horn is able to deliver the CBN tools quickly from stock. The Supermini system is available in left- and right-hand versions with different corner radii. The CBN-tipped variants are for internal machining from a diameter of 2mm. Different lengths of solid carbide body are available. Tools in the Mini family can be used from an internal diameter of 6.8mm and are also available in left- and right-hand versions. The single-edged tool type 315 is for external grooving from a width of 0.5mm. In the cutting insert system 229, the previous CBN substrate CB 50 is replaced by the higher performance substrate CB 35. Inserts are available with two different corner radii and cutting widths from 3mm to 6mm. CBN is the second-hardest material after diamond. Tools made from CBN wear much more slowly than other cutting materials when used appropriately. It is consequently possible to achieve higher dimensional and profile accuracy, even when machining hard materials such as steel up to 70 HRC. There are no different grades of CBN. Differentiation between tools is down to the CBN volume fraction, the fillers, grain size and the ceramic/metallic binder phase (cobalt/nickel). This results in different CBN substrates. Hard machining is usually carried out without coolant, as these cutting materials have high heat resistance and the elevated temperature within the chip formation zone has a positive effect. Whereas carbide suffers a significant loss of hardness at around 800°C, the hardness of CBN remains almost unchanged at temperatures up to 1,200°C. Another significant advantage is good chemical resistance, even at these high temperatures. www.phorn.co.uk

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

The Boeing X-37B spaceplane is to begin executing a series of novel manoeuvres, called aerobraking, to change its orbit around Earth, the US Space Force has announced.

When Puneet and Neelam Neotia moved from India to the United States several years ago, they brought with them a family background in manufacturing and CNC machining. Now the couple is working to get their startup machine shop off the ground, sourcing new customers and getting the word out about their shop in Clarksville, Indiana. The couple — proud to publicize their "Made in the USA" parts — is leveraging family connections and manufacturing capabilities back in India, but not in the way that some people assume.

When it comes to utilizing the spindle’s power, there is a lot of headroom at the upper limits, provided it’s in short bursts. Be mindful of your time at these loads so you don’t stall out.

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

Join Mahr for an informative webinar to discover the latest advancements in precision measurement, designed to elevate your quality assurance processes and unlock peak productivity. It'll explore cutting-edge technologies — such as modern height gages and contour measuring systems — along with their applications, benefits and technical capabilities. Discover the power of height gages: Learn how intuitive and sophisticated height gages can revolutionize your measurement processes, enabling quick and accurate results in inspection and production areas. Explore the practical functions and ease of use that make height gages an ideal solution for manufacturers seeking high-performance and reliable measuring technology. Examine sample applications and industries where height gages excel, such as qualifying first parts, inspecting incoming parts and measuring series of parts in industries like aerospace, automotive and medical. Unlock efficient contour measurement: An introduction to the latest contour measuring technologies that enable fast, simple and comprehensive contour measurement in the production environment. Discover how these innovative solutions ensure reliable measurements, saving time and increasing efficiency while measuring a wide range of workpieces. Learn how to streamline your contour measuring process with speed and simplicity, achieving fast and precise measurements with incredible versatility. Register now and discover how to unlock peak productivity with new innovations in precision measurement. Agenda: Insights into the latest precision measurement technologies and their applications Understanding of how to improve quality assurance processes and increase productivity Knowledge of how to select the right measurement solutions for your specific needs Tips on how to optimize your measurement processes for maximum efficiency

Ingersoll has fully embraced this machining strategy, announcing the release and updates of dozens of high-feed cutting tools in many sizes over the course of the evening. Dubbing these new high-feed options the WinSFeed line, it combines the tool life of the SFeed material grades with high-feed geometries.

The Supermini system is available in left- and right-hand versions with different corner radii. The CBN-tipped variants are for internal machining from a diameter of 2mm. Different lengths of solid carbide body are available. Tools in the Mini family can be used from an internal diameter of 6.8mm and are also available in left- and right-hand versions.

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.

Ceratizit USA has promoted Troy Wilt from national sales manager to managing director of Ceratizit USA, cutting tools division.

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

Barrel cutters — also known as circle-segment cutters — are end mills with conical shapes designed to replace ballnose end mills in five-axis machining applications, especially in the aerospace and die/mold industries. They are known for large stepovers that dramatically improve cycle time, which is why Harpaz believes they will only grow in popularity.

CBN is the second-hardest material after diamond. Tools made from CBN wear much more slowly than other cutting materials when used appropriately. It is consequently possible to achieve higher dimensional and profile accuracy, even when machining hard materials such as steel up to 70 HRC.

Working closely with customers and making careful investments has enabled this Wisconsin machine shop to tackle difficult jobs with tight deadlines as a core part of its business.

Whereas carbide suffers a significant loss of hardness at around 800°C, the hardness of CBN remains almost unchanged at temperatures up to 1,200°C. Another significant advantage is good chemical resistance, even at these high temperatures.

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.

Horn has announced an expansion of its product portfolio to include tools tipped with cubic boron nitride (CBN) for machining difficult materials, such as superalloys and hardened steels.

Weldon Solutions is demonstrating three grinders at IMTS 2024. Though they differ in size and use case, all feature the company’s hallmark customizations.

If you find this article informative, consider subscribing digitally to Aerospace Manufacturing for free. Keep up to date with the latest industry news in your inbox as well as being the first to receive our magazine in digital form.

With nearly every tool discussed, Harpaz emphasized the shallow depth of cut and constant feed rate, hammering home the company’s confidence in high-feed milling. He even advised using the higher tool life of the lines on display to push the cutting tools even harder. “It’s not about saving tool costs, but reducing production costs,” he says. Doing so reduces the tool life to what might be expected without the treatment, but increases productivity and therefore profitability, in his opinion.

In celebration of World Space Week, Space-Comm Expo has announced visitor registration is now officially live and open for the London ExCeL, event, running 11-12 March 2025.

Features that save on training, programming and cycle times have enabled Speedway Motors to rapidly grow and mature its manufacturing arm.

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.

Understanding all the things that contribute to a machine’s full potential accuracy will inform what to prioritize when fine-tuning the machine.

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

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

The single-edged tool type 315 is for external grooving from a width of 0.5mm. In the cutting insert system 229, the previous CBN substrate CB 50 is replaced by the higher performance substrate CB 35. Inserts are available with two different corner radii and cutting widths from 3mm to 6mm.

The event saw dozens of new cutting tool options, including numerous high-feed machining inserts, modular milling options, drills, and tools for turning, parting and grooving. Photo Credit: Ingersoll

Did you know that the show was postponed for WWII? Or that McCormick Place was expanded in the ’70s just to accommodate IMTS? A fascinating look at the show’s history from 1927 to today.

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

CoroMill MS 20 is designed for repeated shoulder milling, face milling, linear and helical ramping, full slotting and plunging applications.

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.

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

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

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

With all these cutting tools on display, it was difficult for any one cutter to stand out, but Harpaz’s excitement for barrel-style cutters was especially high.

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

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.

Indexable Mills Speed Cavity Cutting - ball nose insert milling cutter

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