New Tool, New Strategy Allow Five Times Faster Roughing

Laser calibration of a machine tool hardly proceeds at light speed. For example, bi-directional laser calibration of just one 40-inch axis of a CNC mill might take the better part of an hour, with the machine axis moving in 10-mm increments and stopping to settle as the laser interferometer takes each reading. That pause for each reading can be as long as 23 seconds, says Renishaw, a supplier of machine calibration technology including laser systems. The cumulative effect of all of these little waits can translate to considerable downtime for calibrating a large, high-value machine tool. In some cases,—depending on machine crashes and the shop’s quality system, the company says—a critical machine might be out Carbide Threading Inserts of action for several days per year just for this calibration. Owners of these machines are obviously very aware of the lost production.

But there is a solution, Renishaw says. A technique taking advantage of a feature in its XL80 laser interferometer reduces the settling time to just 250 milliseconds after each incremental axis move, cutting calibration time by 85 to 95 percent. In addition to returning the machine to production more quickly, this technique also better reflects axis positioning accuracy under real cutting conditions, because in real cutting, the moves are fast and the settling time is slight before the tool engages the work.

Quality Tech Services of Byron, Georgia, uses this time-saving technique with the XL80. The company has instructed new laser buyers on using it as well. Company owner Mike Schraufnagel shoulder milling cutters says, “As a calibration service, the first concern we hear when we walk in the door is downtime on a machine. Customers will do anything to cut downtime on a critical asset.” His customers who own lasers themselves have employed this technique to keep their machines cutting, while his own team uses it to increase its overall efficiency. “What normally would take 30 minutes now takes just 3,” he says. “In one afternoon, we were able to complete six laser setups and three ballbar setups on a machine in 2 hours.” In the past, this work would have taken at least a day.

An M code and an open contact relay are the prerequisites that make this technique possible. To achieve the high speed calibration, the machine’s CNC uses an available M code to close a “normally open” set of relay contacts for between 10 and 20 milliseconds. If the M code to effect this trigger is not available, it might be available for purchase or activation through the OEM. Closure of the relay contacts via an auxiliary I/O cable provides a trigger for the laser to record the difference between the measurement reading and the target position.  

“We identified spare relays that can be controlled via M codes on a Haas CNC machine in our lab,” explains Michael Wilm, Renishaw’s calibration business manager. Using the relays to trigger the laser interferometer and thereby reduce machine downtime was the idea that developed from this discovery. The laser simply needs to see the relay close for as little as a microsecond, but mechanical relay contacts can bounce for the first few milliseconds, he says. Therefore, “we have added a bounce rejection feature programmed into the electronics of the laser. Any chatter within 20 milliseconds gets ignored, the laser takes a reading, and the axis moves to the next measuring position.” The result is laser calibration that proceeds quickly, and more like the way the machine will move during normal production. 

The Cemented Carbide Blog: high feed milling Insert

Laser calibration of a machine tool hardly proceeds at light speed. For example, bi-directional laser calibration of just one 40-inch axis of a CNC mill might take the better part of an hour, with the machine axis moving in 10-mm increments and stopping to settle as the laser interferometer takes each reading. That pause for each reading can be as long as 23 seconds, says Renishaw, a supplier of machine calibration technology including laser systems. The cumulative effect of all of these little waits can translate to considerable downtime for calibrating a large, high-value machine tool. In some cases,—depending on machine crashes and the shop’s quality system, the company says—a critical machine might be out Carbide Threading Inserts of action for several days per year just for this calibration. Owners of these machines are obviously very aware of the lost production.

But there is a solution, Renishaw says. A technique taking advantage of a feature in its XL80 laser interferometer reduces the settling time to just 250 milliseconds after each incremental axis move, cutting calibration time by 85 to 95 percent. In addition to returning the machine to production more quickly, this technique also better reflects axis positioning accuracy under real cutting conditions, because in real cutting, the moves are fast and the settling time is slight before the tool engages the work.

Quality Tech Services of Byron, Georgia, uses this time-saving technique with the XL80. The company has instructed new laser buyers on using it as well. Company owner Mike Schraufnagel shoulder milling cutters says, “As a calibration service, the first concern we hear when we walk in the door is downtime on a machine. Customers will do anything to cut downtime on a critical asset.” His customers who own lasers themselves have employed this technique to keep their machines cutting, while his own team uses it to increase its overall efficiency. “What normally would take 30 minutes now takes just 3,” he says. “In one afternoon, we were able to complete six laser setups and three ballbar setups on a machine in 2 hours.” In the past, this work would have taken at least a day.

An M code and an open contact relay are the prerequisites that make this technique possible. To achieve the high speed calibration, the machine’s CNC uses an available M code to close a “normally open” set of relay contacts for between 10 and 20 milliseconds. If the M code to effect this trigger is not available, it might be available for purchase or activation through the OEM. Closure of the relay contacts via an auxiliary I/O cable provides a trigger for the laser to record the difference between the measurement reading and the target position.  

“We identified spare relays that can be controlled via M codes on a Haas CNC machine in our lab,” explains Michael Wilm, Renishaw’s calibration business manager. Using the relays to trigger the laser interferometer and thereby reduce machine downtime was the idea that developed from this discovery. The laser simply needs to see the relay close for as little as a microsecond, but mechanical relay contacts can bounce for the first few milliseconds, he says. Therefore, “we have added a bounce rejection feature programmed into the electronics of the laser. Any chatter within 20 milliseconds gets ignored, the laser takes a reading, and the axis moves to the next measuring position.” The result is laser calibration that proceeds quickly, and more like the way the machine will move during normal production. 

The Cemented Carbide Blog: high feed milling Insert

Laser calibration of a machine tool hardly proceeds at light speed. For example, bi-directional laser calibration of just one 40-inch axis of a CNC mill might take the better part of an hour, with the machine axis moving in 10-mm increments and stopping to settle as the laser interferometer takes each reading. That pause for each reading can be as long as 23 seconds, says Renishaw, a supplier of machine calibration technology including laser systems. The cumulative effect of all of these little waits can translate to considerable downtime for calibrating a large, high-value machine tool. In some cases,—depending on machine crashes and the shop’s quality system, the company says—a critical machine might be out Carbide Threading Inserts of action for several days per year just for this calibration. Owners of these machines are obviously very aware of the lost production.

But there is a solution, Renishaw says. A technique taking advantage of a feature in its XL80 laser interferometer reduces the settling time to just 250 milliseconds after each incremental axis move, cutting calibration time by 85 to 95 percent. In addition to returning the machine to production more quickly, this technique also better reflects axis positioning accuracy under real cutting conditions, because in real cutting, the moves are fast and the settling time is slight before the tool engages the work.

Quality Tech Services of Byron, Georgia, uses this time-saving technique with the XL80. The company has instructed new laser buyers on using it as well. Company owner Mike Schraufnagel shoulder milling cutters says, “As a calibration service, the first concern we hear when we walk in the door is downtime on a machine. Customers will do anything to cut downtime on a critical asset.” His customers who own lasers themselves have employed this technique to keep their machines cutting, while his own team uses it to increase its overall efficiency. “What normally would take 30 minutes now takes just 3,” he says. “In one afternoon, we were able to complete six laser setups and three ballbar setups on a machine in 2 hours.” In the past, this work would have taken at least a day.

An M code and an open contact relay are the prerequisites that make this technique possible. To achieve the high speed calibration, the machine’s CNC uses an available M code to close a “normally open” set of relay contacts for between 10 and 20 milliseconds. If the M code to effect this trigger is not available, it might be available for purchase or activation through the OEM. Closure of the relay contacts via an auxiliary I/O cable provides a trigger for the laser to record the difference between the measurement reading and the target position.  

“We identified spare relays that can be controlled via M codes on a Haas CNC machine in our lab,” explains Michael Wilm, Renishaw’s calibration business manager. Using the relays to trigger the laser interferometer and thereby reduce machine downtime was the idea that developed from this discovery. The laser simply needs to see the relay close for as little as a microsecond, but mechanical relay contacts can bounce for the first few milliseconds, he says. Therefore, “we have added a bounce rejection feature programmed into the electronics of the laser. Any chatter within 20 milliseconds gets ignored, the laser takes a reading, and the axis moves to the next measuring position.” The result is laser calibration that proceeds quickly, and more like the way the machine will move during normal production. 

The Cemented Carbide Blog: high feed milling Insert

Heavy Duty, High Precision CNC Centers

Walter USA gun drilling inserts has expanded its solid-carbide micro drill line with the addition of the DB131 Supreme micro pilot drill sizes and extended the DB133 Supreme micro drill offering to deep drills up to 30 × DC. According to Walter, these new drills are designed to help achieve maximum process reliability with minimal dimensional variations and extended tool life in steel, cast iron, nonferrous, super alloys, hard materials and other materials (ISO P, K, N, S, H and O). Stainless steel (ISO M) is added to the list with internal coolant capability.

The use of Walter grades WJ30EL and WJ30ER is said to ensure that the drills provide superior wear resistance. In addition, the optimal cutting-edge preparation on the drill provide excellent surface finishes.

A new type of flute design reliably evacuates chips, even with the tinniest drills. VNMG Insert This capability ensures that hole depths up to 30 × DC can be easily achieved with the DB133 Supreme micro drill with its 140° point angle. The DB131 Supreme micro pilot drill features a 150° point angle. Emulsion, oil or minimum-quantity lubrication (MQL) can all be used as a coolant with these drills.

The new DB133 drills without internal coolant are available in a diameter range from 0.020-0.116". (0.5-2.95 mm). The diameter range for the micro drills with internal coolant is 0.028-0.116". (0.7-2.95 mm). Length to diameter ratios (L/D) of 5, 8, 12, 16, 20, 25 and 30 × Dc are standard for micro drills with internal coolant and 5 and 8 × DC without internal coolant. This new drill design is effective for applications in the medical, watchmaking, general mechanical engineering, mold and die making, energy and automotive industries.

The Cemented Carbide Blog: ccmg Insert

Walter USA gun drilling inserts has expanded its solid-carbide micro drill line with the addition of the DB131 Supreme micro pilot drill sizes and extended the DB133 Supreme micro drill offering to deep drills up to 30 × DC. According to Walter, these new drills are designed to help achieve maximum process reliability with minimal dimensional variations and extended tool life in steel, cast iron, nonferrous, super alloys, hard materials and other materials (ISO P, K, N, S, H and O). Stainless steel (ISO M) is added to the list with internal coolant capability.

The use of Walter grades WJ30EL and WJ30ER is said to ensure that the drills provide superior wear resistance. In addition, the optimal cutting-edge preparation on the drill provide excellent surface finishes.

A new type of flute design reliably evacuates chips, even with the tinniest drills. VNMG Insert This capability ensures that hole depths up to 30 × DC can be easily achieved with the DB133 Supreme micro drill with its 140° point angle. The DB131 Supreme micro pilot drill features a 150° point angle. Emulsion, oil or minimum-quantity lubrication (MQL) can all be used as a coolant with these drills.

The new DB133 drills without internal coolant are available in a diameter range from 0.020-0.116". (0.5-2.95 mm). The diameter range for the micro drills with internal coolant is 0.028-0.116". (0.7-2.95 mm). Length to diameter ratios (L/D) of 5, 8, 12, 16, 20, 25 and 30 × Dc are standard for micro drills with internal coolant and 5 and 8 × DC without internal coolant. This new drill design is effective for applications in the medical, watchmaking, general mechanical engineering, mold and die making, energy and automotive industries.

The Cemented Carbide Blog: ccmg Insert

Walter USA gun drilling inserts has expanded its solid-carbide micro drill line with the addition of the DB131 Supreme micro pilot drill sizes and extended the DB133 Supreme micro drill offering to deep drills up to 30 × DC. According to Walter, these new drills are designed to help achieve maximum process reliability with minimal dimensional variations and extended tool life in steel, cast iron, nonferrous, super alloys, hard materials and other materials (ISO P, K, N, S, H and O). Stainless steel (ISO M) is added to the list with internal coolant capability.

The use of Walter grades WJ30EL and WJ30ER is said to ensure that the drills provide superior wear resistance. In addition, the optimal cutting-edge preparation on the drill provide excellent surface finishes.

A new type of flute design reliably evacuates chips, even with the tinniest drills. VNMG Insert This capability ensures that hole depths up to 30 × DC can be easily achieved with the DB133 Supreme micro drill with its 140° point angle. The DB131 Supreme micro pilot drill features a 150° point angle. Emulsion, oil or minimum-quantity lubrication (MQL) can all be used as a coolant with these drills.

The new DB133 drills without internal coolant are available in a diameter range from 0.020-0.116". (0.5-2.95 mm). The diameter range for the micro drills with internal coolant is 0.028-0.116". (0.7-2.95 mm). Length to diameter ratios (L/D) of 5, 8, 12, 16, 20, 25 and 30 × Dc are standard for micro drills with internal coolant and 5 and 8 × DC without internal coolant. This new drill design is effective for applications in the medical, watchmaking, general mechanical engineering, mold and die making, energy and automotive industries.

The Cemented Carbide Blog: ccmg Insert

Cutting Tools Developed to Machine Heat Resistant Alloys

Root form slots found in turbine rotors are characterized by complex contours and precise dimensions. “Christmas tree” form tools used to cut those intricate slots must be precisely ground so no portion of their profile pushes through their tight tolerance band. Consequently, setting up grinding machines to repeatedly VBMT Insert deliver quality root form tools is often challenging and time-consuming.

These setups typically involve grinding a trial tool, measuring the tool to identify the portions of the profile that are out of tolerance, and manually tweaking the machine and/or part program to compensate for grinding discrepancies. Depending on the application, this setup procedure can take hours.

The automated Form Tool Compensation (FTC) system developed by Walter (a United Grinding company) offers a more streamlined way to set up these jobs while ensuring ground profile accuracy to as little as 2 microns. By shortening, simplifying and automating the setup process, this technology minimizes turnaround time for manufacturers currently producing such complex root form tools and opens up opportunities for those hoping to enter this market.

The FTC system is available for use with the company’s Helitronic grinding machines and supports three tool grinding methods: faceted relief, cam relief and cylindrical grinding. The heart of the system is measurement/program compensation software that links the grinding machine and a tool measuring device. Tool measurement can be performed using one of the company’s standalone Helicheck scanning machines or a portable, on-machine scanning unit Walter recently introduced.

After a preliminary tool is ground to its upper tolerance, the measuring device (either a Helicheck or the on-machine scanning unit) scans the tool’s entire profile without any operator involvement. (It takes 5 minutes to scan a 60-mm profile.) The FTC software then compares the measured profile to the CAD model and automatically creates and sends compensation corrections to the grinding machine’s control. At this point, the grinding machine is ready for a production run.

When a Helicheck is used as the accompanying measuring device, FTC can deliver a ground profile accuracy within 2 microns. When the on-machine scanning unit is used, FTC is only minimally less accurate at 3 microns. However, the on-machine scanning unit can be used on multiple Helitronic machines and costs less than standalone equipment. The on-machine measuring unit consists of a high speed CCD camera coupled with a collimated LED backlight. The backlight allows the camera to reliably distinguish a tool’s cutting edge regardless of tool material or surface finish. The unit installs in the grinding machine’s head in RCMX Insert less than one minute without calibration thanks to a self-centering interface. It uses air nozzles to automatically clean tools before performing its scanning routines. After the unit measures a tool, it is removed to allow grinding to be performed.

The on-machine FTC version is offered as an option on new Helitronic machines. It currently can’t be adapted for use with older Helitronic machines because a different grinding head design is needed to allow the head to accept the scanning unit.

The Cemented Carbide Blog: threading Insert

Root form slots found in turbine rotors are characterized by complex contours and precise dimensions. “Christmas tree” form tools used to cut those intricate slots must be precisely ground so no portion of their profile pushes through their tight tolerance band. Consequently, setting up grinding machines to repeatedly VBMT Insert deliver quality root form tools is often challenging and time-consuming.

These setups typically involve grinding a trial tool, measuring the tool to identify the portions of the profile that are out of tolerance, and manually tweaking the machine and/or part program to compensate for grinding discrepancies. Depending on the application, this setup procedure can take hours.

The automated Form Tool Compensation (FTC) system developed by Walter (a United Grinding company) offers a more streamlined way to set up these jobs while ensuring ground profile accuracy to as little as 2 microns. By shortening, simplifying and automating the setup process, this technology minimizes turnaround time for manufacturers currently producing such complex root form tools and opens up opportunities for those hoping to enter this market.

The FTC system is available for use with the company’s Helitronic grinding machines and supports three tool grinding methods: faceted relief, cam relief and cylindrical grinding. The heart of the system is measurement/program compensation software that links the grinding machine and a tool measuring device. Tool measurement can be performed using one of the company’s standalone Helicheck scanning machines or a portable, on-machine scanning unit Walter recently introduced.

After a preliminary tool is ground to its upper tolerance, the measuring device (either a Helicheck or the on-machine scanning unit) scans the tool’s entire profile without any operator involvement. (It takes 5 minutes to scan a 60-mm profile.) The FTC software then compares the measured profile to the CAD model and automatically creates and sends compensation corrections to the grinding machine’s control. At this point, the grinding machine is ready for a production run.

When a Helicheck is used as the accompanying measuring device, FTC can deliver a ground profile accuracy within 2 microns. When the on-machine scanning unit is used, FTC is only minimally less accurate at 3 microns. However, the on-machine scanning unit can be used on multiple Helitronic machines and costs less than standalone equipment. The on-machine measuring unit consists of a high speed CCD camera coupled with a collimated LED backlight. The backlight allows the camera to reliably distinguish a tool’s cutting edge regardless of tool material or surface finish. The unit installs in the grinding machine’s head in RCMX Insert less than one minute without calibration thanks to a self-centering interface. It uses air nozzles to automatically clean tools before performing its scanning routines. After the unit measures a tool, it is removed to allow grinding to be performed.

The on-machine FTC version is offered as an option on new Helitronic machines. It currently can’t be adapted for use with older Helitronic machines because a different grinding head design is needed to allow the head to accept the scanning unit.

The Cemented Carbide Blog: threading Insert

Root form slots found in turbine rotors are characterized by complex contours and precise dimensions. “Christmas tree” form tools used to cut those intricate slots must be precisely ground so no portion of their profile pushes through their tight tolerance band. Consequently, setting up grinding machines to repeatedly VBMT Insert deliver quality root form tools is often challenging and time-consuming.

These setups typically involve grinding a trial tool, measuring the tool to identify the portions of the profile that are out of tolerance, and manually tweaking the machine and/or part program to compensate for grinding discrepancies. Depending on the application, this setup procedure can take hours.

The automated Form Tool Compensation (FTC) system developed by Walter (a United Grinding company) offers a more streamlined way to set up these jobs while ensuring ground profile accuracy to as little as 2 microns. By shortening, simplifying and automating the setup process, this technology minimizes turnaround time for manufacturers currently producing such complex root form tools and opens up opportunities for those hoping to enter this market.

The FTC system is available for use with the company’s Helitronic grinding machines and supports three tool grinding methods: faceted relief, cam relief and cylindrical grinding. The heart of the system is measurement/program compensation software that links the grinding machine and a tool measuring device. Tool measurement can be performed using one of the company’s standalone Helicheck scanning machines or a portable, on-machine scanning unit Walter recently introduced.

After a preliminary tool is ground to its upper tolerance, the measuring device (either a Helicheck or the on-machine scanning unit) scans the tool’s entire profile without any operator involvement. (It takes 5 minutes to scan a 60-mm profile.) The FTC software then compares the measured profile to the CAD model and automatically creates and sends compensation corrections to the grinding machine’s control. At this point, the grinding machine is ready for a production run.

When a Helicheck is used as the accompanying measuring device, FTC can deliver a ground profile accuracy within 2 microns. When the on-machine scanning unit is used, FTC is only minimally less accurate at 3 microns. However, the on-machine scanning unit can be used on multiple Helitronic machines and costs less than standalone equipment. The on-machine measuring unit consists of a high speed CCD camera coupled with a collimated LED backlight. The backlight allows the camera to reliably distinguish a tool’s cutting edge regardless of tool material or surface finish. The unit installs in the grinding machine’s head in RCMX Insert less than one minute without calibration thanks to a self-centering interface. It uses air nozzles to automatically clean tools before performing its scanning routines. After the unit measures a tool, it is removed to allow grinding to be performed.

The on-machine FTC version is offered as an option on new Helitronic machines. It currently can’t be adapted for use with older Helitronic machines because a different grinding head design is needed to allow the head to accept the scanning unit.

The Cemented Carbide Blog: threading Insert

Induction Braze Carbide Inserts to Prevent Defects in Tool Tips

Kaiser Tool’s Groove ‘N Turn line includes the Thinbit tools with right-hand, counter-clockwise face grooving inserts. The tools are designed to cut internal face grooves with major diameters starting at 0.300". The Groove TCMT Insert ‘N Turn inserts are available in 0.004" through 0.150" in 0.001" increments with options including sharp corner through full radius. Major diameters are offered in 0.300"Carbide Turning Inserts , 0.750", 1.250" and 3.000". These inserts are made from sub-micron grain carbide with grades for ferrous and non-ferrous materials, either uncoated or with TiN, TiCN, TiAIN, or diamond film coatings.

The inserts can be used in conventional, Swiss-type and CNC machines. Toolholders are available in square shank sizes 5/16" through 1¼", and round shank sizes ½" through 1" with straight and 90-degree presentations. Groove ‘N Turn inserts fit all L-series toolholders and modifications can be provided on any Thinbit tooling.

The Cemented Carbide Blog: Carbide Inserts

Kaiser Tool’s Groove ‘N Turn line includes the Thinbit tools with right-hand, counter-clockwise face grooving inserts. The tools are designed to cut internal face grooves with major diameters starting at 0.300". The Groove TCMT Insert ‘N Turn inserts are available in 0.004" through 0.150" in 0.001" increments with options including sharp corner through full radius. Major diameters are offered in 0.300"Carbide Turning Inserts , 0.750", 1.250" and 3.000". These inserts are made from sub-micron grain carbide with grades for ferrous and non-ferrous materials, either uncoated or with TiN, TiCN, TiAIN, or diamond film coatings.

The inserts can be used in conventional, Swiss-type and CNC machines. Toolholders are available in square shank sizes 5/16" through 1¼", and round shank sizes ½" through 1" with straight and 90-degree presentations. Groove ‘N Turn inserts fit all L-series toolholders and modifications can be provided on any Thinbit tooling.

The Cemented Carbide Blog: Carbide Inserts

Kaiser Tool’s Groove ‘N Turn line includes the Thinbit tools with right-hand, counter-clockwise face grooving inserts. The tools are designed to cut internal face grooves with major diameters starting at 0.300". The Groove TCMT Insert ‘N Turn inserts are available in 0.004" through 0.150" in 0.001" increments with options including sharp corner through full radius. Major diameters are offered in 0.300"Carbide Turning Inserts , 0.750", 1.250" and 3.000". These inserts are made from sub-micron grain carbide with grades for ferrous and non-ferrous materials, either uncoated or with TiN, TiCN, TiAIN, or diamond film coatings.

The inserts can be used in conventional, Swiss-type and CNC machines. Toolholders are available in square shank sizes 5/16" through 1¼", and round shank sizes ½" through 1" with straight and 90-degree presentations. Groove ‘N Turn inserts fit all L-series toolholders and modifications can be provided on any Thinbit tooling.

The Cemented Carbide Blog: Carbide Inserts

There are several types of milling cutters

Carbide threading inserts are cutting tools used in machining operations to create threads on various materials, such as metals and plastics. They are commonly used in lathes, milling machines, and CNC (Computer Numerical Control) machines.Carbide threading inserts are made from cemented carbide, which is a composite material composed of tungsten carbide particles bonded together with a metal binder, typically cobalt. The combination of tungsten carbide's hardness and wear resistance, along with the toughness of the metal binder, makes carbide inserts highly suitable for cutting applications.These inserts feature specially designed cutting edges and chip breakers that enable efficient chip evacuation and improved cutting performance. The threading inserts are available in various shapes and sizes to accommodate different thread profiles, such as internal threads (taps) or external threads (dies).Carbide threading inserts offer several advantages over traditional high-speed steel (HSS) tools. They have superior hardness and wear resistance, allowing for higher cutting speeds and longer tool life. Carbide inserts also provide excellent heat resistance, reducing the likelihood of tool failure due to excessive heat buildup during cutting. Additionally, they exhibit good dimensional accuracy and repeatability, resulting in precise thread profiles.When using carbide threading inserts, it's essential to consider factors such as cutting speed, feed Carbide Turning Inserts rate, and depth of cut to optimize the cutting process and achieve the desired thread quality. The appropriate insert geometry, coating, and cutting parameters depend on the specific material being threaded and the thread specifications.Overall, carbide threading inserts are widely used in manufacturing and machining industries due to their durability, performance, and versatility in creating accurate threads.Related search keywords:Carbide threading inserts, carbide threading inserts manufacturers in china, carbide inserts, carbide cutter, carbide inserts for threading, threading insert, carbide insert, carbide milling cutter, threading with carbide inserts, thread cutting, carbide parts, tungsten carbide tools, carbide inserts manufacturers, carbide inserts for wood, carbide inserts for aluminum, carbide inserts suppliers, carbide Carbide Milling Insert inserts for sale, carbide inserts for hardened steel, carbide inserts for lathe, carbide inserts angles, carbide inserts apkt, carbide inserts for aluminium, carbide inserts for a lathe
The Cemented Carbide Blog: Carbide Drilling Inserts Carbide threading inserts are cutting tools used in machining operations to create threads on various materials, such as metals and plastics. They are commonly used in lathes, milling machines, and CNC (Computer Numerical Control) machines.Carbide threading inserts are made from cemented carbide, which is a composite material composed of tungsten carbide particles bonded together with a metal binder, typically cobalt. The combination of tungsten carbide's hardness and wear resistance, along with the toughness of the metal binder, makes carbide inserts highly suitable for cutting applications.These inserts feature specially designed cutting edges and chip breakers that enable efficient chip evacuation and improved cutting performance. The threading inserts are available in various shapes and sizes to accommodate different thread profiles, such as internal threads (taps) or external threads (dies).Carbide threading inserts offer several advantages over traditional high-speed steel (HSS) tools. They have superior hardness and wear resistance, allowing for higher cutting speeds and longer tool life. Carbide inserts also provide excellent heat resistance, reducing the likelihood of tool failure due to excessive heat buildup during cutting. Additionally, they exhibit good dimensional accuracy and repeatability, resulting in precise thread profiles.When using carbide threading inserts, it's essential to consider factors such as cutting speed, feed Carbide Turning Inserts rate, and depth of cut to optimize the cutting process and achieve the desired thread quality. The appropriate insert geometry, coating, and cutting parameters depend on the specific material being threaded and the thread specifications.Overall, carbide threading inserts are widely used in manufacturing and machining industries due to their durability, performance, and versatility in creating accurate threads.Related search keywords:Carbide threading inserts, carbide threading inserts manufacturers in china, carbide inserts, carbide cutter, carbide inserts for threading, threading insert, carbide insert, carbide milling cutter, threading with carbide inserts, thread cutting, carbide parts, tungsten carbide tools, carbide inserts manufacturers, carbide inserts for wood, carbide inserts for aluminum, carbide inserts suppliers, carbide Carbide Milling Insert inserts for sale, carbide inserts for hardened steel, carbide inserts for lathe, carbide inserts angles, carbide inserts apkt, carbide inserts for aluminium, carbide inserts for a lathe
The Cemented Carbide Blog: Carbide Drilling Inserts Carbide threading inserts are cutting tools used in machining operations to create threads on various materials, such as metals and plastics. They are commonly used in lathes, milling machines, and CNC (Computer Numerical Control) machines.Carbide threading inserts are made from cemented carbide, which is a composite material composed of tungsten carbide particles bonded together with a metal binder, typically cobalt. The combination of tungsten carbide's hardness and wear resistance, along with the toughness of the metal binder, makes carbide inserts highly suitable for cutting applications.These inserts feature specially designed cutting edges and chip breakers that enable efficient chip evacuation and improved cutting performance. The threading inserts are available in various shapes and sizes to accommodate different thread profiles, such as internal threads (taps) or external threads (dies).Carbide threading inserts offer several advantages over traditional high-speed steel (HSS) tools. They have superior hardness and wear resistance, allowing for higher cutting speeds and longer tool life. Carbide inserts also provide excellent heat resistance, reducing the likelihood of tool failure due to excessive heat buildup during cutting. Additionally, they exhibit good dimensional accuracy and repeatability, resulting in precise thread profiles.When using carbide threading inserts, it's essential to consider factors such as cutting speed, feed Carbide Turning Inserts rate, and depth of cut to optimize the cutting process and achieve the desired thread quality. The appropriate insert geometry, coating, and cutting parameters depend on the specific material being threaded and the thread specifications.Overall, carbide threading inserts are widely used in manufacturing and machining industries due to their durability, performance, and versatility in creating accurate threads.Related search keywords:Carbide threading inserts, carbide threading inserts manufacturers in china, carbide inserts, carbide cutter, carbide inserts for threading, threading insert, carbide insert, carbide milling cutter, threading with carbide inserts, thread cutting, carbide parts, tungsten carbide tools, carbide inserts manufacturers, carbide inserts for wood, carbide inserts for aluminum, carbide inserts suppliers, carbide Carbide Milling Insert inserts for sale, carbide inserts for hardened steel, carbide inserts for lathe, carbide inserts angles, carbide inserts apkt, carbide inserts for aluminium, carbide inserts for a lathe
The Cemented Carbide Blog: Carbide Drilling Inserts

How does the choice of carbide grade affect the performance and tool life of a t

To manufacture a large Lockheed Martin component, JWF Industries, based in Johnstown, Pennsylvania, purchased what is probably the largest machine in the region, says owner Bill Polacek. However, the machine itself was only part of the solution. The company also needed long-reach tooling to cut the large part. By working with cutting tool supplier Sandvik Coromant (Fair Lawn, New Jersey) and paying attention to the tool-up process, JWF was able to keep production in-house and shave weeks off of the expected production time.

What started as a one-man garage shop in 1957 by John Polacek Sr. has become a diversified contract manufacturer that makes parts and assemblies for large commercial OEMs and defense prime contractors. The company produces everything from small to very large components, but most products are medium-size. Through the years, constant change has forced JWF to adapt. For instance, only two to three years ago, 70 percent of the business was defense. Today, that mix has changed, and commercial equipment comprises about 70 percent of the business. With almost 1 million square feet of facility space and 425 employees, JWF is able to take on large projects. One component, though, had Mr. Polacek wondering if he had bitten off more than he could chew.

That component was an 8-foot by 18-foot Lockheed Martin frame used as a platform for radar assemblies. JWF invested close to $3 million in an MCR double-column gantry with a 26-foot table from Okuma (Charlotte, North Carolina), in part, with the Lockheed Martin project in mind. Because of this, machine optimization was crucial. JWF also invested in elaborate fixturing to hold the frame part.

Machining the frame required long-reach boring, milling and drilling tools—some extending well over the gauge line. Mr. Polacek needed a secure process and tooling selection, and he needed it quickly. JWF was under the gun to produce the first-piece runoff and inspection in order to assure the customer that the frame’s machining phase was low risk. The machine was installed in late fall and the clock was ticking for a January 2012 deadline.

To optimize the process, he called in John Dolan, productivity engineer at Sandvik Coromant, to look at the specs, the product, the carbon steel workpiece and the application. Mr. Dolan’s first recommendation was a different tooling setup. Several milling and boring features on the frame component required long overhangs ranging from 8 to 28 inches from gauge line. To boost productivity, Mr. Dolan suggested a damped Sandvik Coromant milling adapter combined with the CoroMill 490 and CoroMill 390. The positive rake angle and free-cutting geometry backed by shim protection on the CoroMill 490 enabled support features to be milled on the frame. Also, the CoroMill 490 achieved 32 finishes out of the box. With the damped adapter, JWF can run aggressively at 500 sfm and 0.006-inch fpt. One milling-specific feature required a large corner radius on the inserts, which are standard products for Sandvik Coromant product.

Boring the front knuckle required a tight hole tolerance through 10 inches of gauge length. Sandvik Coromant’s DuoBore 870 damped unit enabled operators to bore at high surface footage and feed rates while maintaining straightness and hole quality. Also, the CoroMill 390 face mill and CoroMill 216 ball mill were productive in milling the steering knuckle features and radii.

As a defense project, datum points were critical on this project. The points required 0.001-inch flatness tolerances and 125 RMA surface finishes. Thousands of datum points needed to be inspected, which required zero-defect manufacturing. To produce these specs on material that is only 0.375-inch thick on a weldment, the company used a 1.5-inch-diameter CoroMill 490 with 14-mm inserts that feature PL grade 1030 coating. The positive rake and geometry of the cutter gave operators the tolerance and finish necessary to mill the 0.25-MIN-in.-thick datum. Working with JWF methods engineer and programmer Tom Robine, Mr. Dolan tried different programming techniques, and a spiral morph pattern provided the productivity needed without putting unwanted tooling pressure on the thin gauge material.

The most challenging part on the frame, from a tooling standpoint, was a series of slots on the side. The tool needed to extend about 28 inches from the gage line. Using Coromant Capto C8 extensions, Mr. Robine and Mr. Dolan built out an exchangeable-tip CoroMill 316 so they could reach under features on the frame to mill the slots. Though they relied on the steep taper CAT 50 at the spindle, the tool assembly was able to ramp-mill the slots while still running elevated cutting data. Having the strongest coupling available also boosted productivity.

“The exchangeable-head end mills can be simply unscrewed when worn, and replaced without setting the tool length offset,” Mr. Robine says. “Any time you don’t have to measure a 28-inch tool, the risk of tool damage is reduced, and you get productivity gains for keeping the machine making chips.”

Using CoroMill 460, 870 and 880, Mr. Robine and Mr. Dolan ran some 360 sfm and feed rates of 0.008 CNC Carbide Tool Insert to 0.012 ipr to drill various holes. This made drilling the frame components a time-saver, since no spot drilling or peck drilling was needed. Though speed was an important factor, being able to drill through 120 feet of material on the edge was also extremely important because having to change out tools is costly and time consuming. The extended tool life equated to better cycle times and more green-light production. That durability teamed with Sandvik CoroTap taps, which run between 84 to 112 sfm, made holemaking extremely productive, the company says.

JWF produced the first piece runoff in record time. The first piece, which is usually machined more slowly than production, was still finished two weeks faster than when the company was outsourcing the machining hundreds of miles away. With the project now being Cermet Inserts completed in-house, JWF has the ability to machine three frames in the time it once took to machine one frame, and the company has control over its own process.

According to the company, one key to its success was buying the right tools from the start. It was nearly a $30,000 investment, but considering the size of the contract and the cost of the machine bought to accomplish it, getting into production without delay was essential. 

The Cemented Carbide Blog: tungsten carbide cutting tools

To manufacture a large Lockheed Martin component, JWF Industries, based in Johnstown, Pennsylvania, purchased what is probably the largest machine in the region, says owner Bill Polacek. However, the machine itself was only part of the solution. The company also needed long-reach tooling to cut the large part. By working with cutting tool supplier Sandvik Coromant (Fair Lawn, New Jersey) and paying attention to the tool-up process, JWF was able to keep production in-house and shave weeks off of the expected production time.

What started as a one-man garage shop in 1957 by John Polacek Sr. has become a diversified contract manufacturer that makes parts and assemblies for large commercial OEMs and defense prime contractors. The company produces everything from small to very large components, but most products are medium-size. Through the years, constant change has forced JWF to adapt. For instance, only two to three years ago, 70 percent of the business was defense. Today, that mix has changed, and commercial equipment comprises about 70 percent of the business. With almost 1 million square feet of facility space and 425 employees, JWF is able to take on large projects. One component, though, had Mr. Polacek wondering if he had bitten off more than he could chew.

That component was an 8-foot by 18-foot Lockheed Martin frame used as a platform for radar assemblies. JWF invested close to $3 million in an MCR double-column gantry with a 26-foot table from Okuma (Charlotte, North Carolina), in part, with the Lockheed Martin project in mind. Because of this, machine optimization was crucial. JWF also invested in elaborate fixturing to hold the frame part.

Machining the frame required long-reach boring, milling and drilling tools—some extending well over the gauge line. Mr. Polacek needed a secure process and tooling selection, and he needed it quickly. JWF was under the gun to produce the first-piece runoff and inspection in order to assure the customer that the frame’s machining phase was low risk. The machine was installed in late fall and the clock was ticking for a January 2012 deadline.

To optimize the process, he called in John Dolan, productivity engineer at Sandvik Coromant, to look at the specs, the product, the carbon steel workpiece and the application. Mr. Dolan’s first recommendation was a different tooling setup. Several milling and boring features on the frame component required long overhangs ranging from 8 to 28 inches from gauge line. To boost productivity, Mr. Dolan suggested a damped Sandvik Coromant milling adapter combined with the CoroMill 490 and CoroMill 390. The positive rake angle and free-cutting geometry backed by shim protection on the CoroMill 490 enabled support features to be milled on the frame. Also, the CoroMill 490 achieved 32 finishes out of the box. With the damped adapter, JWF can run aggressively at 500 sfm and 0.006-inch fpt. One milling-specific feature required a large corner radius on the inserts, which are standard products for Sandvik Coromant product.

Boring the front knuckle required a tight hole tolerance through 10 inches of gauge length. Sandvik Coromant’s DuoBore 870 damped unit enabled operators to bore at high surface footage and feed rates while maintaining straightness and hole quality. Also, the CoroMill 390 face mill and CoroMill 216 ball mill were productive in milling the steering knuckle features and radii.

As a defense project, datum points were critical on this project. The points required 0.001-inch flatness tolerances and 125 RMA surface finishes. Thousands of datum points needed to be inspected, which required zero-defect manufacturing. To produce these specs on material that is only 0.375-inch thick on a weldment, the company used a 1.5-inch-diameter CoroMill 490 with 14-mm inserts that feature PL grade 1030 coating. The positive rake and geometry of the cutter gave operators the tolerance and finish necessary to mill the 0.25-MIN-in.-thick datum. Working with JWF methods engineer and programmer Tom Robine, Mr. Dolan tried different programming techniques, and a spiral morph pattern provided the productivity needed without putting unwanted tooling pressure on the thin gauge material.

The most challenging part on the frame, from a tooling standpoint, was a series of slots on the side. The tool needed to extend about 28 inches from the gage line. Using Coromant Capto C8 extensions, Mr. Robine and Mr. Dolan built out an exchangeable-tip CoroMill 316 so they could reach under features on the frame to mill the slots. Though they relied on the steep taper CAT 50 at the spindle, the tool assembly was able to ramp-mill the slots while still running elevated cutting data. Having the strongest coupling available also boosted productivity.

“The exchangeable-head end mills can be simply unscrewed when worn, and replaced without setting the tool length offset,” Mr. Robine says. “Any time you don’t have to measure a 28-inch tool, the risk of tool damage is reduced, and you get productivity gains for keeping the machine making chips.”

Using CoroMill 460, 870 and 880, Mr. Robine and Mr. Dolan ran some 360 sfm and feed rates of 0.008 CNC Carbide Tool Insert to 0.012 ipr to drill various holes. This made drilling the frame components a time-saver, since no spot drilling or peck drilling was needed. Though speed was an important factor, being able to drill through 120 feet of material on the edge was also extremely important because having to change out tools is costly and time consuming. The extended tool life equated to better cycle times and more green-light production. That durability teamed with Sandvik CoroTap taps, which run between 84 to 112 sfm, made holemaking extremely productive, the company says.

JWF produced the first piece runoff in record time. The first piece, which is usually machined more slowly than production, was still finished two weeks faster than when the company was outsourcing the machining hundreds of miles away. With the project now being Cermet Inserts completed in-house, JWF has the ability to machine three frames in the time it once took to machine one frame, and the company has control over its own process.

According to the company, one key to its success was buying the right tools from the start. It was nearly a $30,000 investment, but considering the size of the contract and the cost of the machine bought to accomplish it, getting into production without delay was essential. 

The Cemented Carbide Blog: tungsten carbide cutting tools

To manufacture a large Lockheed Martin component, JWF Industries, based in Johnstown, Pennsylvania, purchased what is probably the largest machine in the region, says owner Bill Polacek. However, the machine itself was only part of the solution. The company also needed long-reach tooling to cut the large part. By working with cutting tool supplier Sandvik Coromant (Fair Lawn, New Jersey) and paying attention to the tool-up process, JWF was able to keep production in-house and shave weeks off of the expected production time.

What started as a one-man garage shop in 1957 by John Polacek Sr. has become a diversified contract manufacturer that makes parts and assemblies for large commercial OEMs and defense prime contractors. The company produces everything from small to very large components, but most products are medium-size. Through the years, constant change has forced JWF to adapt. For instance, only two to three years ago, 70 percent of the business was defense. Today, that mix has changed, and commercial equipment comprises about 70 percent of the business. With almost 1 million square feet of facility space and 425 employees, JWF is able to take on large projects. One component, though, had Mr. Polacek wondering if he had bitten off more than he could chew.

That component was an 8-foot by 18-foot Lockheed Martin frame used as a platform for radar assemblies. JWF invested close to $3 million in an MCR double-column gantry with a 26-foot table from Okuma (Charlotte, North Carolina), in part, with the Lockheed Martin project in mind. Because of this, machine optimization was crucial. JWF also invested in elaborate fixturing to hold the frame part.

Machining the frame required long-reach boring, milling and drilling tools—some extending well over the gauge line. Mr. Polacek needed a secure process and tooling selection, and he needed it quickly. JWF was under the gun to produce the first-piece runoff and inspection in order to assure the customer that the frame’s machining phase was low risk. The machine was installed in late fall and the clock was ticking for a January 2012 deadline.

To optimize the process, he called in John Dolan, productivity engineer at Sandvik Coromant, to look at the specs, the product, the carbon steel workpiece and the application. Mr. Dolan’s first recommendation was a different tooling setup. Several milling and boring features on the frame component required long overhangs ranging from 8 to 28 inches from gauge line. To boost productivity, Mr. Dolan suggested a damped Sandvik Coromant milling adapter combined with the CoroMill 490 and CoroMill 390. The positive rake angle and free-cutting geometry backed by shim protection on the CoroMill 490 enabled support features to be milled on the frame. Also, the CoroMill 490 achieved 32 finishes out of the box. With the damped adapter, JWF can run aggressively at 500 sfm and 0.006-inch fpt. One milling-specific feature required a large corner radius on the inserts, which are standard products for Sandvik Coromant product.

Boring the front knuckle required a tight hole tolerance through 10 inches of gauge length. Sandvik Coromant’s DuoBore 870 damped unit enabled operators to bore at high surface footage and feed rates while maintaining straightness and hole quality. Also, the CoroMill 390 face mill and CoroMill 216 ball mill were productive in milling the steering knuckle features and radii.

As a defense project, datum points were critical on this project. The points required 0.001-inch flatness tolerances and 125 RMA surface finishes. Thousands of datum points needed to be inspected, which required zero-defect manufacturing. To produce these specs on material that is only 0.375-inch thick on a weldment, the company used a 1.5-inch-diameter CoroMill 490 with 14-mm inserts that feature PL grade 1030 coating. The positive rake and geometry of the cutter gave operators the tolerance and finish necessary to mill the 0.25-MIN-in.-thick datum. Working with JWF methods engineer and programmer Tom Robine, Mr. Dolan tried different programming techniques, and a spiral morph pattern provided the productivity needed without putting unwanted tooling pressure on the thin gauge material.

The most challenging part on the frame, from a tooling standpoint, was a series of slots on the side. The tool needed to extend about 28 inches from the gage line. Using Coromant Capto C8 extensions, Mr. Robine and Mr. Dolan built out an exchangeable-tip CoroMill 316 so they could reach under features on the frame to mill the slots. Though they relied on the steep taper CAT 50 at the spindle, the tool assembly was able to ramp-mill the slots while still running elevated cutting data. Having the strongest coupling available also boosted productivity.

“The exchangeable-head end mills can be simply unscrewed when worn, and replaced without setting the tool length offset,” Mr. Robine says. “Any time you don’t have to measure a 28-inch tool, the risk of tool damage is reduced, and you get productivity gains for keeping the machine making chips.”

Using CoroMill 460, 870 and 880, Mr. Robine and Mr. Dolan ran some 360 sfm and feed rates of 0.008 CNC Carbide Tool Insert to 0.012 ipr to drill various holes. This made drilling the frame components a time-saver, since no spot drilling or peck drilling was needed. Though speed was an important factor, being able to drill through 120 feet of material on the edge was also extremely important because having to change out tools is costly and time consuming. The extended tool life equated to better cycle times and more green-light production. That durability teamed with Sandvik CoroTap taps, which run between 84 to 112 sfm, made holemaking extremely productive, the company says.

JWF produced the first piece runoff in record time. The first piece, which is usually machined more slowly than production, was still finished two weeks faster than when the company was outsourcing the machining hundreds of miles away. With the project now being Cermet Inserts completed in-house, JWF has the ability to machine three frames in the time it once took to machine one frame, and the company has control over its own process.

According to the company, one key to its success was buying the right tools from the start. It was nearly a $30,000 investment, but considering the size of the contract and the cost of the machine bought to accomplish it, getting into production without delay was essential. 

The Cemented Carbide Blog: tungsten carbide cutting tools