Indexable Tools Designed to Maximize Performance - milling insert types

 2024-08-07 03:48:10

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.

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.

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!

Scot Forge is a diversified, employee-owned forging company that has been in business for more than 100 years. It has plants in Clinton, Wisconsin as well as Franklin Park and Spring Grove, Illinois. By customer preference, most of the company’s output is delivered in the forged and rough-machined condition. Howard Dempsey is supervisor of the machine and saw shop at the Clinton plant, a site that runs 24 hours a day, five days a week and houses 200 employees, 50 of whom are machinists. He says the part that prompted the company’s switch to Hex-Turn is just one of a growing number of jobs involving high-temperature alloys, which management has identified as a trend. “We get about six reorders a year for that part, and orders for other Inconel and titanium forgings are rising,” he notes. “So, we decided it was time to develop a best practice for machining them.”

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.

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

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

Ingersoll product manager Raymon Avery adds that the other difference-maker is the 45-degree lead angle, which is made intrinsically possible by the insert’s hex shape and chipbreaker top face. This lead angle provides a gentler entry into the work that reduces cutting forces and protects the insert. Meanwhile, the contoured top face breaks up the long, hot, gummy chips characteristic of Inconel alloys and deflects them away from the insert to reduce heat.

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.

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.

In all, the drop-in retooling saved $1,500 in cycle time and $900 in tooling costs—per part. Cost savings aside, having a secure process for such difficult material enables Scot Forge to bid more confidently on Inconel jobs and to compete more effectively in a high-tech niche. “This improvement enables us to maintain competitive costs for machining Inconel,” Mr. Dempsey says. “Otherwise, we would have been forced to raise prices to cover the excessive cost of tooling and the resulting sub-par productivity.”

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.

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.

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.

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.

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.

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

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.

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

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.

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

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.

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.

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.

That was the case with Scot Forge’s problem component, a huge Inconel No 7718 hub used in nuclear turbomachinery. This part requires rough turning and facing to remove about 0.8 inch of material across its entire diameter, primarily for truing up. As forged, it measures 98 inches in diameter, with a step-down to a 93-inch diameter on one end.

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

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

This is the first year that Seco Tools UK has been nominated for this award. We are delighted that Seco Tools UK has been recognised by its employees as an organisation that promotes a healthy workplace culture through trust, pride and camaraderie. According to the Great Place to Work Trust Index Survey conducted in October 2019, 89% of employees agree that Seco is a great place to work. One employee says Seco has “great family spirit,” adding “we have the freedom to decide what our best contribution is to the business.”

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.

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

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.

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

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.

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

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

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.

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

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.

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.

There are many reasons Seco Tools UK was recognised in this year's UK Best Workplaces ranking along with 161 other UK organisations. Specifically, efforts related to corporate social responsibility, an exceptional work environment and excellent employee engagement set Seco Tools UK apart. This is the first year that Seco Tools UK has been nominated for this award. We are delighted that Seco Tools UK has been recognised by its employees as an organisation that promotes a healthy workplace culture through trust, pride and camaraderie. According to the Great Place to Work Trust Index Survey conducted in October 2019, 89% of employees agree that Seco is a great place to work. One employee says Seco has “great family spirit,” adding “we have the freedom to decide what our best contribution is to the business.” Understanding the perspective of employees is key to building a successful workplace environment. To determine an organisation’s ranking, Great Place to Work administers their Trust Index Survey to employees which represents 3/4 of the final score. Zoe Wood, HR manager at Seco Tools UK, explained that employee engagement is “not just about a regular pay cheque, a secure job, having an annual performance review... those things are important, but they are just a starting point. In 2020, our work means more to us – it’s about feeling a passion for what you do, knowing that your work is developing you as a person, both professionally and personally. It’s about feeling coached and supported, it’s knowing your job is more than just a job – it’s a life choice.” The remaining quarter of the score comes from the Culture Audit, a business-driven questionnaire that uncovers and evaluates the organisation's HR and leadership practices, policies and culture. www.secotools.com

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."

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?

Following Mr. Whitley’s advice paid dividends at Scot Forge, which saved $2,400 per part on one tough Inconel turning application after retooling to Ingersoll’s Hex-Turn inserts and adjusting machining parameters accordingly. Based on its success with that job, the company has standardized on Hex-Turn and those same parameters for rough turning a growing variety of Inconel parts.

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

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.

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

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

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

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

With an eye toward a better standard practice for turning this class of alloy, Mr. Dempsey asked all his tooling vendors for their best ideas and began testing different solutions. Most tools the company tested produced minor improvements at best. The exception was the Hex-Turn, which features a 45-degree lead angle presentation and top-face chipbreakers. Tests showed these inserts could significantly improve cycle time and tool life compared to the square, flat-topped, zero-lead models the shop had been using.

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

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

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.

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.

Sherman D’Souza will provide global customers with access to Rego-Fix research, development and technical support teams to create and supply toolholding solutions.

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.

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.

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.

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

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.

The large Inconel hub requires rough turning and facing to remove about 0.8 inch of material across its entire diameter. As forged, it measures 98 inches in diameter, with a step-down to a 93-inch diameter on one end.

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.

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

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.

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

The remaining quarter of the score comes from the Culture Audit, a business-driven questionnaire that uncovers and evaluates the organisation's HR and leadership practices, policies and culture.

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

Scot Forge’s Brandon James indexes a Hex-Turn insert, which will last reliably through the entire machining process on the big Inconel forging. The shop’s previous, square inserts typically failed after just one inch of feed.

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.

Thanks to a 45-degree lead angle and top-face chipbreaker, the Hex-Turn inserts outlast their predecessors by 69 to 1 while reducing cycle time on the Inconel forging by 15 hours.

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.

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

Cutting deeper reduces the number of required passes, which, in turn, reduces the insert’s exposure to the hot, abrasive environment at the cutting edge. However, as Mr. Whitley explains, an insert’s ability to withstand a deeper cut depends on its strength. That’s why—true to its name—the Hex-Turn features a hexagonal geometry, a shape that is second only to round inserts in strength, he says.

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.

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.

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 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.

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

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

While taking on Inconel, titanium and other high-temperature alloys can provide a competitive advantage and a source of pride, these exotic materials are abrasive to tools and impose high cutting forces. Additionally, they tend to generate hot, stringy chips that can stick to the cutting edge and overheat the tool. As a result, such work can create bottlenecks, tie up machines and increase tooling costs.

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).

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

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

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.

The company standardized parameters for the new tool at an 0.015-ipr feed rate (slightly less than the previous rate), an 0.15-inch cutting depth (double the previous setting) and a speed of 60 sfm (60 percent higher than the previous setting). Despite more than doubling the cutting rate, each insert lasted through the whole part. Cycle time dropped 15 percent. “We would have been happy with just the tool life improvement,” Mr. Dempsey says. “The throughput gain was an unexpected bonus.”

Once it had a bird’s eye view of various data points across its shops, this aerospace manufacturer raised its utilization by 27% in nine months.

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

By changing to a hex-shaped turning insert with a 45-degree lead angle, this shop saved thousands of dollars on a difficult Inconel turning application.

When inserts rupture in Inconel, the typical reaction is to “take the load off” the insert by lightening the cut, says Jim Whitley of cutting tool manufacturer Ingersoll (Rockford, Illinois). However, this reaction may be ill-advised. Shops tend to forget that rupture often begins with an edge going dull, which, in turn, overloads the insert to the point of breaking down. “This can happen within a few seconds, so it’s easy to miss wear as the root cause,” he explains. “Assuming that adequate machine horsepower is available, the better answer is to go to a stronger insert with a gentle lead angle and make fewer, deeper passes.”

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

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

Previously, machining took 105 hours and 40 passes at a feed rate of 0.02 ipr, a cutting depth of 0.075 inch and a speed of 38 sfm. The turning and facing operations required different inserts, and the job typically ate through 69 inserts per part. In fact, tool failure was so prevalent that inserts required indexing every half inch, and the job had to be run 100-percent attended. Moreover, the main failure mode was edge rupture, which renders the insert useless even if some edges go unused. All the while, the operation tied up a large vertical lathe from MAG Giddings & Lewis (Fond du Lac, Wisconsin) that the company needed for other work.

Ingersoll’s Raymon Avery and Scot Forge’s Howard Dempsey stand amid finished Inconel hubs while discussing how to tackle the next tooling issue. Mr. Avery or his colleague Jim Whitley meet regularly with Scot Forge representatives to stay ahead of the curve in production planning.

Zoe Wood, HR manager at Seco Tools UK, explained that employee engagement is “not just about a regular pay cheque, a secure job, having an annual performance review... those things are important, but they are just a starting point. In 2020, our work means more to us – it’s about feeling a passion for what you do, knowing that your work is developing you as a person, both professionally and personally. It’s about feeling coached and supported, it’s knowing your job is more than just a job – it’s a life choice.”

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

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.

Understanding the perspective of employees is key to building a successful workplace environment. To determine an organisation’s ranking, Great Place to Work administers their Trust Index Survey to employees which represents 3/4 of the final score.

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

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

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

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.

Indexable Tools Designed to Maximize Performance - milling insert types

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