Tornos Swiss ST26 Offers Turnkey Equipment Packs

Jet Edge’s high-rail-gantry waterjet motion system is designed for use in high-production industrial waterjet shops that require performance, precision and accuracy. This waterjet system supports as many as 12 cutting heads for maximum throughput, enabling shops to process jobs faster and take in more work. It is available in sizes ranging from 4 × 4 ft. to 24 × 14 ft. (1,200 × 1,200 mm to 7,300 × 4,200 mm). The machine features a 12" or 18" Z axis (300 or 455 mm), and an extra 3" (75 mm) TNGG Insert of travel can be added with an optional sub-Z assembly.

According to Jet Edge, the gantry system provides ±0.001" linear positional accuracy (over 12") per axis, ±0.001" repeatability (bi-directional) and 0.0004" maximum backlash. A stress-relieved, steel-fabricated frame provides high rigidity, and coupled with rigid, honeycombed steel beams, enables stable and fast operation. Moving elements are supported on THK linear ways. Precision ballscrews are directly coupled to servomotors.

Mechanical components along the X and Y axes are protected from the abrasive jet environment by a lip seal system. This system uses brushes, labyrinth passages, lip seals, and high-volume, low-pressure filtered air to protect critical motion components, providing longer service life compared to conventional bellows arrangements. The system’s overhead design enables full access to the work envelope and raises critical Carbide Inserts components out of the waterjet process environment.

The high-rail-gantry system features Jet Edge’s fully-networkable Aquavision Di controller, which guides the user from job setup to production, including single parts, mirroring, rotation, plate alignment and part arrays. 

The Cemented Carbide Blog: drilling Inserts suppliers

Jet Edge’s high-rail-gantry waterjet motion system is designed for use in high-production industrial waterjet shops that require performance, precision and accuracy. This waterjet system supports as many as 12 cutting heads for maximum throughput, enabling shops to process jobs faster and take in more work. It is available in sizes ranging from 4 × 4 ft. to 24 × 14 ft. (1,200 × 1,200 mm to 7,300 × 4,200 mm). The machine features a 12" or 18" Z axis (300 or 455 mm), and an extra 3" (75 mm) TNGG Insert of travel can be added with an optional sub-Z assembly.

According to Jet Edge, the gantry system provides ±0.001" linear positional accuracy (over 12") per axis, ±0.001" repeatability (bi-directional) and 0.0004" maximum backlash. A stress-relieved, steel-fabricated frame provides high rigidity, and coupled with rigid, honeycombed steel beams, enables stable and fast operation. Moving elements are supported on THK linear ways. Precision ballscrews are directly coupled to servomotors.

Mechanical components along the X and Y axes are protected from the abrasive jet environment by a lip seal system. This system uses brushes, labyrinth passages, lip seals, and high-volume, low-pressure filtered air to protect critical motion components, providing longer service life compared to conventional bellows arrangements. The system’s overhead design enables full access to the work envelope and raises critical Carbide Inserts components out of the waterjet process environment.

The high-rail-gantry system features Jet Edge’s fully-networkable Aquavision Di controller, which guides the user from job setup to production, including single parts, mirroring, rotation, plate alignment and part arrays. 

The Cemented Carbide Blog: drilling Inserts suppliers

Tool Chuck’s Optimal Runout Achieved with Additive Manufacturing

The new Edge2 DSS system from Dapra is designed deep hole drilling inserts to deliver both 90-degree milling performance and good value for an indexable milling product. Double-sided DSS inserts provide four usable cutting edges to lower cost per edge versus single-sided inserts. Additionally, Dapra’s permanent automatic cutter replacement program is intended to make it easier for shops to keep good-condition tools in use rather than making do with worn-out cutters.

The inserts feature a positive geometry for low cutting cemented carbide inserts pressure and maintained strength. Convexity creates smooth surface finishes during step-down profile milling, and a custom-designed wiper edge generates good surface finishes, the company says. These inserts are available in both T-land and dished geometries in a variety of high-performance grades and coatings.

DSS end mills, shell mills and screw-on modular heads are machined from hardened, high-shock tool steel to minimize runout and maximize durability and life. Nickel plating provides a harder casing for improved pocket durability and resistance to chip galling, while deep gullets deliver efficient chip evacuation, even on the heaviest cuts, the company says. Long-reach tools are available with carbide cores for enhanced rigidity and reduced deflection.

The Cemented Carbide Blog: carbide Insert

The new Edge2 DSS system from Dapra is designed deep hole drilling inserts to deliver both 90-degree milling performance and good value for an indexable milling product. Double-sided DSS inserts provide four usable cutting edges to lower cost per edge versus single-sided inserts. Additionally, Dapra’s permanent automatic cutter replacement program is intended to make it easier for shops to keep good-condition tools in use rather than making do with worn-out cutters.

The inserts feature a positive geometry for low cutting cemented carbide inserts pressure and maintained strength. Convexity creates smooth surface finishes during step-down profile milling, and a custom-designed wiper edge generates good surface finishes, the company says. These inserts are available in both T-land and dished geometries in a variety of high-performance grades and coatings.

DSS end mills, shell mills and screw-on modular heads are machined from hardened, high-shock tool steel to minimize runout and maximize durability and life. Nickel plating provides a harder casing for improved pocket durability and resistance to chip galling, while deep gullets deliver efficient chip evacuation, even on the heaviest cuts, the company says. Long-reach tools are available with carbide cores for enhanced rigidity and reduced deflection.

The Cemented Carbide Blog: carbide Insert

Ceratizit Offers Inserts Optimized for Steel Turning

Carbide Drilling Inserts Substrates, coatings, geometries and other aspects of cutting tools keep on getting better. How much time do you spend on evaluating new tools?

In this article, a Boeing plant describes how finding an alternative to its “standard” roughing tool led to a seven-fold improvement in roughing metal removal rate.

In another article, a die shop describes how just keeping current with the improvements in new tools allows the shop to steadily do more work with high speed milling as an alternative to EDM.

There is a trade-off, of course. You need your capacity for today’s jobs—and many of those jobs require the tools you already know well. However, if you don’t evaluate new tools now, then tomorrow’s jobs won’t benefit from what you discover.

What is your shop’s BTA deep hole drilling inserts philosophy on experimenting with new cutting tools? How often do you do this? What kind of process improvements have you made by discovering the latest and best tool for your process?

The Cemented Carbide Blog: carbide insert stock

Carbide Drilling Inserts Substrates, coatings, geometries and other aspects of cutting tools keep on getting better. How much time do you spend on evaluating new tools?

In this article, a Boeing plant describes how finding an alternative to its “standard” roughing tool led to a seven-fold improvement in roughing metal removal rate.

In another article, a die shop describes how just keeping current with the improvements in new tools allows the shop to steadily do more work with high speed milling as an alternative to EDM.

There is a trade-off, of course. You need your capacity for today’s jobs—and many of those jobs require the tools you already know well. However, if you don’t evaluate new tools now, then tomorrow’s jobs won’t benefit from what you discover.

What is your shop’s BTA deep hole drilling inserts philosophy on experimenting with new cutting tools? How often do you do this? What kind of process improvements have you made by discovering the latest and best tool for your process?

The Cemented Carbide Blog: carbide insert stock

Big Kaiser's HDC Jet Through Toolholder Improves Five Axis Surface Finish

FlowXpert 2015, slot milling cutters Flow International Corp.’s upgrade to its FlowXpert software suite, offers new capabilities for 3D pathing and cutting to enable waterjet users to work more effectively in 3D with less complexity. The CAD/CAM software platform expands on the company’s FlowMaster intelligent software suite and includes Design powered by Spaceclaim, an integrated 3D CAD/CAM programming tool with Flow Sequencer. This integration, engineered in partnership with Spaceclaim, increases flexibility and is specifically designed for waterjet cutting, enabling faster waterjet programing. According to Flow, best practices such as waterjet application tips, material cut speed knowledge, improved pathing algorithms and expanded lead in/out customization enables the program to estimate what steps are needed to produce the best part.

The software gravity turning inserts includes a redesigned interface for 2D and 3D part programming. Users are able to design a part and path it in the same program, and it is possible to modify the geometry of a part without losing the path. In most cases, the Sequencer integration will automatically update the path to accommodate the changes, the company says. Additionally, the software detects model and path errors and suggests corrections. Additional features include 3D CAM offset capabilities, versatile sheet metal processing from Spaceclaim, customizable clean-up tools and the capability to save a 3D model as a 2D programmed part.

The Cemented Carbide Blog: grooving Inserts manufacturers

FlowXpert 2015, slot milling cutters Flow International Corp.’s upgrade to its FlowXpert software suite, offers new capabilities for 3D pathing and cutting to enable waterjet users to work more effectively in 3D with less complexity. The CAD/CAM software platform expands on the company’s FlowMaster intelligent software suite and includes Design powered by Spaceclaim, an integrated 3D CAD/CAM programming tool with Flow Sequencer. This integration, engineered in partnership with Spaceclaim, increases flexibility and is specifically designed for waterjet cutting, enabling faster waterjet programing. According to Flow, best practices such as waterjet application tips, material cut speed knowledge, improved pathing algorithms and expanded lead in/out customization enables the program to estimate what steps are needed to produce the best part.

The software gravity turning inserts includes a redesigned interface for 2D and 3D part programming. Users are able to design a part and path it in the same program, and it is possible to modify the geometry of a part without losing the path. In most cases, the Sequencer integration will automatically update the path to accommodate the changes, the company says. Additionally, the software detects model and path errors and suggests corrections. Additional features include 3D CAM offset capabilities, versatile sheet metal processing from Spaceclaim, customizable clean-up tools and the capability to save a 3D model as a 2D programmed part.

The Cemented Carbide Blog: grooving Inserts manufacturers

Tooling System Speeds Change Overs for Swiss Type Lathes

Coolant systems rarely get top billing as the key feature of a machine tool, but that is the case with the lathes and machining centers being introduced to this country by Hakusui USA Inc. (Schaumburg, Illinois). The line of machine tools includes four lathe models and two vertical machining centers. All of the machines have, as a standard feature, a high pressure mist coolant delivery system that creates a mist of ultra-fine water and oil particles. The company claims that this allows for significant increases in surface speed and metal removal rates and longer tool life.

This method of coolant delivery, which the company has dubbed the ECOREG System, mixes a water-based coolant with an oil lubricant in a high pressure air stream, creating extremely small particles. These particles are then injected through high-pressure nozzles designed to be precisely directed to the point of machining.

The coolant is a solution of an anti-corrosive agent and surfactants diluted in water. The ratio of water and solution varies from 20:1 to 30:1. The oil lubricant that the company recommends is a specially formulated vegetable oil but other oils can be used, with those formulated as extreme pressure lubricants being recommended. The advantage of the vegetable oil is that it creates virtually no environmental impact.

One of the main benefits of the system is that is uses very little liquid. The company says that, under typical machining conditions, its lathes consume about one liter of coolant in 55 hours of machining. The VMCs consume approximately the same amount under normal machining conditions. Despite this low usage, the system provides a substantial cooling and lubricating effect.

This effect is apparently due to the almost immediate evaporation of the mist on contact with the workpiece, cutting tool and chip. The misting Carbide Turning Inserts of the liquid increases its surface area, enhancing its capacity to absorb heat. Pinpoint aim of the nozzle is critical however, because the high pressure delivery of the mist blows away chips, which carry off much of the heat generated in machining. High feed rates and spindle speeds, of course, help considerably to keep heat in the chips as they are formed. Because almost all of the mist evaporates so quickly, the chips are dry, aiding their disposal and increasing their value as a recyclable material.

The fine particles in the mist also allow it to penetrate the cutting tool/workpiece interface when injected at high pressure. Apparently, the ECOREG System creates particles that are small enough to enter the gap between tool and workpiece while high pressure overcomes the centrifugal force of the rotating tool or tube process inserts workpiece. Thus, a very small amount of the oil lubricant—0.3 to 0.5 cubic centimeters per minute—can be very effective, the company says.

In addition to the environmental benefits of this system, the company also cites improved machining results. The combination of increased speeds and feeds with the effects of high cooling and excellent lubrication results in better dimensional accuracy of the workpiece, finer surface finish, higher productivity and increased tool life. The company has not published direct comparisons for various applications but is inviting users to submit sample workpieces for testing at the company's technical center in Schaumburg. The company will then report on process improvements to be expected using its machine tools at the recommended settings. An increase in tool life as high as 400 percent is cited in the company's literature as a typical benefit.

Otherwise, the lathes and VMCs to which Hakusui is attaching its ECOREG System are of conventional design. The lathe line includes two 6-inch models, an 8-inch and a 10-inch model. The HL-06 lathe, for example, features 1,181 ipm rapid traverse in X and Z axes, with an optional 6,000 rpm spindle. For this model, the company has published a case history involving a 2.25-inch bar of 303 stainless steel machined with a carbide insert at a depth of cut of 0.04 inch and feed rate of 0.004 inch. With a spindle speed of 2,800 rpm and surface speed 1,680 fpm, resulting surface roughness is given as 0.00006 inch and circularity is given as 0.000031 inch TIR. In another example, the HTL-80, an 8-inch lathe, performed a rough cut on 1046 steel with an 0.08 inch DOC at 1,640 sfm producing a 3.4 micron surface finish. This operation consumed a half ounce of coolant per hour.

The two VMCs in the line are both designated as 40-inch models. The HV-40 is slightly smaller, with 30 by 17.7 by 19.7 inch axis travel and 7.5 hp compared to the HTV-40 with 40 by 20 by 20 inch travel and 10 hp. Both models have optional spindles, with an HTV-1000 model offering 10,000 rpm. All of the Hakusui lathes and VMCs are equipped with Fanuc controls.

The ECOREG System is also available as a stand-alone unit, model MRC21, which can be retrofit to existing machine tools.

The Cemented Carbide Blog: TCGT Insert

Coolant systems rarely get top billing as the key feature of a machine tool, but that is the case with the lathes and machining centers being introduced to this country by Hakusui USA Inc. (Schaumburg, Illinois). The line of machine tools includes four lathe models and two vertical machining centers. All of the machines have, as a standard feature, a high pressure mist coolant delivery system that creates a mist of ultra-fine water and oil particles. The company claims that this allows for significant increases in surface speed and metal removal rates and longer tool life.

This method of coolant delivery, which the company has dubbed the ECOREG System, mixes a water-based coolant with an oil lubricant in a high pressure air stream, creating extremely small particles. These particles are then injected through high-pressure nozzles designed to be precisely directed to the point of machining.

The coolant is a solution of an anti-corrosive agent and surfactants diluted in water. The ratio of water and solution varies from 20:1 to 30:1. The oil lubricant that the company recommends is a specially formulated vegetable oil but other oils can be used, with those formulated as extreme pressure lubricants being recommended. The advantage of the vegetable oil is that it creates virtually no environmental impact.

One of the main benefits of the system is that is uses very little liquid. The company says that, under typical machining conditions, its lathes consume about one liter of coolant in 55 hours of machining. The VMCs consume approximately the same amount under normal machining conditions. Despite this low usage, the system provides a substantial cooling and lubricating effect.

This effect is apparently due to the almost immediate evaporation of the mist on contact with the workpiece, cutting tool and chip. The misting Carbide Turning Inserts of the liquid increases its surface area, enhancing its capacity to absorb heat. Pinpoint aim of the nozzle is critical however, because the high pressure delivery of the mist blows away chips, which carry off much of the heat generated in machining. High feed rates and spindle speeds, of course, help considerably to keep heat in the chips as they are formed. Because almost all of the mist evaporates so quickly, the chips are dry, aiding their disposal and increasing their value as a recyclable material.

The fine particles in the mist also allow it to penetrate the cutting tool/workpiece interface when injected at high pressure. Apparently, the ECOREG System creates particles that are small enough to enter the gap between tool and workpiece while high pressure overcomes the centrifugal force of the rotating tool or tube process inserts workpiece. Thus, a very small amount of the oil lubricant—0.3 to 0.5 cubic centimeters per minute—can be very effective, the company says.

In addition to the environmental benefits of this system, the company also cites improved machining results. The combination of increased speeds and feeds with the effects of high cooling and excellent lubrication results in better dimensional accuracy of the workpiece, finer surface finish, higher productivity and increased tool life. The company has not published direct comparisons for various applications but is inviting users to submit sample workpieces for testing at the company's technical center in Schaumburg. The company will then report on process improvements to be expected using its machine tools at the recommended settings. An increase in tool life as high as 400 percent is cited in the company's literature as a typical benefit.

Otherwise, the lathes and VMCs to which Hakusui is attaching its ECOREG System are of conventional design. The lathe line includes two 6-inch models, an 8-inch and a 10-inch model. The HL-06 lathe, for example, features 1,181 ipm rapid traverse in X and Z axes, with an optional 6,000 rpm spindle. For this model, the company has published a case history involving a 2.25-inch bar of 303 stainless steel machined with a carbide insert at a depth of cut of 0.04 inch and feed rate of 0.004 inch. With a spindle speed of 2,800 rpm and surface speed 1,680 fpm, resulting surface roughness is given as 0.00006 inch and circularity is given as 0.000031 inch TIR. In another example, the HTL-80, an 8-inch lathe, performed a rough cut on 1046 steel with an 0.08 inch DOC at 1,640 sfm producing a 3.4 micron surface finish. This operation consumed a half ounce of coolant per hour.

The two VMCs in the line are both designated as 40-inch models. The HV-40 is slightly smaller, with 30 by 17.7 by 19.7 inch axis travel and 7.5 hp compared to the HTV-40 with 40 by 20 by 20 inch travel and 10 hp. Both models have optional spindles, with an HTV-1000 model offering 10,000 rpm. All of the Hakusui lathes and VMCs are equipped with Fanuc controls.

The ECOREG System is also available as a stand-alone unit, model MRC21, which can be retrofit to existing machine tools.

The Cemented Carbide Blog: TCGT Insert

External Threading Toolholder Directs Coolant to the Cutting Edge

Sandvik Coromant’s CoroCut QD system is designed for machining deep grooves and parting off with long overhangs. Based on the company’s Q-Cut and CoroCut ranges, the system combines tools and inserts with rigid clamping and efficient coolant supply. The tool material offers high fatigue resistance, while the inserts provide quality coating adhesion and high edge-line security for longer tool life in parting off operations. The tool tip seat features a backstop so that the insert stays in position, preventing the Carbide Milling Inserts seat from wearing down when the insert is indexed. Plug-and-play adapters ease the connection of over and under coolant. According to the company, the coolant controls the temperature at the cutting edge to resist wear and promote chip bar peeling inserts evacuation, while the rigid clamping mechanism simplifies insert changes. The system is said to ensure process security and ease handling for increased machining efficiency.

The Cemented Carbide Blog: carbide Insert

Sandvik Coromant’s CoroCut QD system is designed for machining deep grooves and parting off with long overhangs. Based on the company’s Q-Cut and CoroCut ranges, the system combines tools and inserts with rigid clamping and efficient coolant supply. The tool material offers high fatigue resistance, while the inserts provide quality coating adhesion and high edge-line security for longer tool life in parting off operations. The tool tip seat features a backstop so that the insert stays in position, preventing the Carbide Milling Inserts seat from wearing down when the insert is indexed. Plug-and-play adapters ease the connection of over and under coolant. According to the company, the coolant controls the temperature at the cutting edge to resist wear and promote chip bar peeling inserts evacuation, while the rigid clamping mechanism simplifies insert changes. The system is said to ensure process security and ease handling for increased machining efficiency.

The Cemented Carbide Blog: carbide Insert

Swiss Type Lathe Equipped with Lasers for Cutting, Welding

Deep-hole drills are often divided into gun drilling inserts gun drilling inserts external chip removal (also known as gun drill), internal chip removal (often abbreviated as BTA by the International Association of Deep-hole Drilling), nesting or spraying chip removal. This paper mainly introduces the development and application of the principle of deep hole drill with internal chip removal.

Generally speaking, the internal chip removal is better than the external chip removal because the chip is discharged from the drill pipe and does not scrape with the machined surface, so the surface processing quality is higher. The processing aperture range is wider and wider. GermanyWe is a well-known deep hole drilling R&D and manufacturing company. They show that the processing aperture range of the outer chip removal gun drill is 0.5-113, and the diameter range of the inner chip removal BTA solid hole drill is 7.76-350, or up to 700. The reaming drill of BTA can expand the drilled holes, cast holes, rolled holes and other pre-processed holes, and improve its accuracy and surface quality, and its speed in processing. Degree and feed can be higher than drilling.We also includes deep hole drills and broaching and boring cutters (chips in front and back rows) with chips and materials discharged from pipes.

All kinds of BTA hole cutting tools are made up of cutting heads and long hollow drill pipes. The finest of them are welded and the thicker are connected by internal and external rectangular threads. The end of the drill pipe is driven by the clamp drive at the end of the machine tool, and the workpiece is driven by the clamp drive at the front of the machine tool spindle. BTA drill pipe is cylindrical and asymmetric drill pipe with much higher torsional rigidity than gun drill pipe, so it can adapt to complex large diameter deep hole processing. The processing principle of BTA deep hole drill is shown in Fig. 1.

Fig. 1 Principle of Deep Hole Drilling with Chip Removal

From Fig. 1 and Fig. 2, it can be seen that the high-pressure coolant passes through the hydraulic head base supported by the central bracket and the drill sleeve on it and enters the head of the BTA bit through the holes distributed in the drill sleeve. The chips cut by the cutting edge of the head are forced into the drill pipe and discharged backwards to prevent the leakage of the high-pressure coolant lubricant. The indenter base is closely encapsulated with the workpiece and the rear part. Before entering the workpiece, the BTA bit should enter the drill pipe first so that it can get correct orientation and centering. Drilling sleeve has a high accuracy requirement. Generally speaking, it is required to reach F7 level. When drilling quality is high, it should reach G6 level. BTA bit is very long. In order to prevent vibration and deflection of drill pipe, the machine tool uses a number of special damping supports with vibration reduction function. Deep hole processing can be either tool rotation or workpiece rotation, or both rotate in opposite direction. Linear feeding is accomplished by the cutter, depending on whether the drill pipe rotates or not, the structure of drill sleeve and damping support of hydraulic bit base. It’s different. The coaxiality of each support is required to hold the drill pipe precisely and consistently, and the back end of the drill pipe is clamped by a special clamping device on the machine tool. The diameter below? 56 can be clamped by cylinder, and the larger clamp with slotted jacket. With this method, the hole depth can reach 250 *D. This machine tool can also be equipped with drills, broaching and boring tools and deep hole drills with flat or spherical bottom of the hole can be machined. The machining accuracy of BTA deep hole processing tool hole ofWe can reach IT6-9 level. The deviation of center line after processing is related to the machine tool, tool, process method and related cutting parameters. In the process method, generally only the workpiece rotates best, and the workpiece rotates opposite to the drill bit. Secondly, the bit rotation is poor. Compared with BTA solid deep hole drill, the tool used in hole processing is the worst, reaming drill, and broaching boring tool is the best.

Figure 2 Deep Hole Drilling Machine Tool

Botek’s BTA bits and reaming drills are of many types, and the number of blades with smaller diameters is less, so only one can be used. The tip of the blade is staggered from the axis, and the guide bar has two pieces. The number of blades and the number of derivatives should gradually increase with the increase of diameter. The layout of the wrong teeth of the blade can vary from one blade to six blades, and the number of derivatives can also increase from two to six blades. The advantages of using guide are as follows: shortening the overhang length and increasing the rigidity of the blade, keeping short overhang and high rigidity at the cutting head when drilling and enlarging deep holes, which can ensure the stability and high accuracy of deep holes. Rigidity improvement restrains vibration, so it is possible to use sharper cutters. Improve the quality and efficiency of processing, adjust the tool outside the production line, adjust accurately and save time. Figure 2 also shows that the guide bars only support the head of the deep hole drill, while the longer part of the drill pipe is supported by damping. If the length L of the unsupported drill pipe is too long, the drill pipe may flutter due to flexion and centrifugal force.We has the recommended value according to the different diameter of drill pipe, and the number of damper supports should be set according to the recommended value.

Figure 3 Several BTA deep hole drill bits

Fig. 4 Several kinds of BTA reaming bit

The examples of BTA deep-hole drill and reaming drill bits are shown in figs. 3 and 4 respectively. The indexable inserts for processing different materials can be made of different materials. After wearing and tearing, the inserts and guide bars can be adjusted and replaced. The adjustment range varies according to different diameters and structures, and the replacement accuracy can reach (+0.01). Except for the above, examples of large diameter broaching and boring cutters (20-222.99) and sleeve drills (55-412.99) are shown in figs. 5 and 6. Deep hole drilling and expanding are driven forward by the cutter, while deep hole boring is the workpiece rotation, the cutter is pulled forward and sent forward, the hole is expanded and the accuracy is improved. This method produces the highest hole accuracy, up to IT7 to IT6. Its size adjustment range is 5 mm, and the offset of center line is the smallest among several methods. The machining principle of sleeve drill is shown in Fig. 6. The tool cuts only the outer wall part of the hole and pulls out the center part of the hole. The cutting power is smaller than that of drilling, energy saving, electricity saving and chip removal. The slot milling cutters sleeve bar can also be used as other parts, especially for processing precious materials.

Fig. 5 Broaching and Boring Head

Fig. 6 Material sets and drills

When BTA deep-hole cutting tools are processed, they must have a complete cooling fluid supply system. Coolants with different flow rates and pressures are needed for deep-hole processing of different kinds of tools with different apertures.We has provided relevant tables and recommended data for each type of cutting tools in advance. Suitable cutting speed and feed per turn are provided for different processed materials, as well as suitable blades and recommended chip breaker type. In order to enable users to achieve smooth processing,and solve the problem of large diameter deep hole processing.

The Cemented Carbide Blog: carbide insert manufacturers

Deep-hole drills are often divided into gun drilling inserts gun drilling inserts external chip removal (also known as gun drill), internal chip removal (often abbreviated as BTA by the International Association of Deep-hole Drilling), nesting or spraying chip removal. This paper mainly introduces the development and application of the principle of deep hole drill with internal chip removal.

Generally speaking, the internal chip removal is better than the external chip removal because the chip is discharged from the drill pipe and does not scrape with the machined surface, so the surface processing quality is higher. The processing aperture range is wider and wider. GermanyWe is a well-known deep hole drilling R&D and manufacturing company. They show that the processing aperture range of the outer chip removal gun drill is 0.5-113, and the diameter range of the inner chip removal BTA solid hole drill is 7.76-350, or up to 700. The reaming drill of BTA can expand the drilled holes, cast holes, rolled holes and other pre-processed holes, and improve its accuracy and surface quality, and its speed in processing. Degree and feed can be higher than drilling.We also includes deep hole drills and broaching and boring cutters (chips in front and back rows) with chips and materials discharged from pipes.

All kinds of BTA hole cutting tools are made up of cutting heads and long hollow drill pipes. The finest of them are welded and the thicker are connected by internal and external rectangular threads. The end of the drill pipe is driven by the clamp drive at the end of the machine tool, and the workpiece is driven by the clamp drive at the front of the machine tool spindle. BTA drill pipe is cylindrical and asymmetric drill pipe with much higher torsional rigidity than gun drill pipe, so it can adapt to complex large diameter deep hole processing. The processing principle of BTA deep hole drill is shown in Fig. 1.

Fig. 1 Principle of Deep Hole Drilling with Chip Removal

From Fig. 1 and Fig. 2, it can be seen that the high-pressure coolant passes through the hydraulic head base supported by the central bracket and the drill sleeve on it and enters the head of the BTA bit through the holes distributed in the drill sleeve. The chips cut by the cutting edge of the head are forced into the drill pipe and discharged backwards to prevent the leakage of the high-pressure coolant lubricant. The indenter base is closely encapsulated with the workpiece and the rear part. Before entering the workpiece, the BTA bit should enter the drill pipe first so that it can get correct orientation and centering. Drilling sleeve has a high accuracy requirement. Generally speaking, it is required to reach F7 level. When drilling quality is high, it should reach G6 level. BTA bit is very long. In order to prevent vibration and deflection of drill pipe, the machine tool uses a number of special damping supports with vibration reduction function. Deep hole processing can be either tool rotation or workpiece rotation, or both rotate in opposite direction. Linear feeding is accomplished by the cutter, depending on whether the drill pipe rotates or not, the structure of drill sleeve and damping support of hydraulic bit base. It’s different. The coaxiality of each support is required to hold the drill pipe precisely and consistently, and the back end of the drill pipe is clamped by a special clamping device on the machine tool. The diameter below? 56 can be clamped by cylinder, and the larger clamp with slotted jacket. With this method, the hole depth can reach 250 *D. This machine tool can also be equipped with drills, broaching and boring tools and deep hole drills with flat or spherical bottom of the hole can be machined. The machining accuracy of BTA deep hole processing tool hole ofWe can reach IT6-9 level. The deviation of center line after processing is related to the machine tool, tool, process method and related cutting parameters. In the process method, generally only the workpiece rotates best, and the workpiece rotates opposite to the drill bit. Secondly, the bit rotation is poor. Compared with BTA solid deep hole drill, the tool used in hole processing is the worst, reaming drill, and broaching boring tool is the best.

Figure 2 Deep Hole Drilling Machine Tool

Botek’s BTA bits and reaming drills are of many types, and the number of blades with smaller diameters is less, so only one can be used. The tip of the blade is staggered from the axis, and the guide bar has two pieces. The number of blades and the number of derivatives should gradually increase with the increase of diameter. The layout of the wrong teeth of the blade can vary from one blade to six blades, and the number of derivatives can also increase from two to six blades. The advantages of using guide are as follows: shortening the overhang length and increasing the rigidity of the blade, keeping short overhang and high rigidity at the cutting head when drilling and enlarging deep holes, which can ensure the stability and high accuracy of deep holes. Rigidity improvement restrains vibration, so it is possible to use sharper cutters. Improve the quality and efficiency of processing, adjust the tool outside the production line, adjust accurately and save time. Figure 2 also shows that the guide bars only support the head of the deep hole drill, while the longer part of the drill pipe is supported by damping. If the length L of the unsupported drill pipe is too long, the drill pipe may flutter due to flexion and centrifugal force.We has the recommended value according to the different diameter of drill pipe, and the number of damper supports should be set according to the recommended value.

Figure 3 Several BTA deep hole drill bits

Fig. 4 Several kinds of BTA reaming bit

The examples of BTA deep-hole drill and reaming drill bits are shown in figs. 3 and 4 respectively. The indexable inserts for processing different materials can be made of different materials. After wearing and tearing, the inserts and guide bars can be adjusted and replaced. The adjustment range varies according to different diameters and structures, and the replacement accuracy can reach (+0.01). Except for the above, examples of large diameter broaching and boring cutters (20-222.99) and sleeve drills (55-412.99) are shown in figs. 5 and 6. Deep hole drilling and expanding are driven forward by the cutter, while deep hole boring is the workpiece rotation, the cutter is pulled forward and sent forward, the hole is expanded and the accuracy is improved. This method produces the highest hole accuracy, up to IT7 to IT6. Its size adjustment range is 5 mm, and the offset of center line is the smallest among several methods. The machining principle of sleeve drill is shown in Fig. 6. The tool cuts only the outer wall part of the hole and pulls out the center part of the hole. The cutting power is smaller than that of drilling, energy saving, electricity saving and chip removal. The slot milling cutters sleeve bar can also be used as other parts, especially for processing precious materials.

Fig. 5 Broaching and Boring Head

Fig. 6 Material sets and drills

When BTA deep-hole cutting tools are processed, they must have a complete cooling fluid supply system. Coolants with different flow rates and pressures are needed for deep-hole processing of different kinds of tools with different apertures.We has provided relevant tables and recommended data for each type of cutting tools in advance. Suitable cutting speed and feed per turn are provided for different processed materials, as well as suitable blades and recommended chip breaker type. In order to enable users to achieve smooth processing,and solve the problem of large diameter deep hole processing.

The Cemented Carbide Blog: carbide insert manufacturers

Tungaloy's Modular Turning System Extends Tool Life

Star SU offers the Bourn and Koch 400 H seven-axis horizontal hobbing machine featuring a FANUC CNC and point-to-point array hobbing capability. The machine is designed for longer spline shafts as well as spur and helical gears ranging to 400 mm in diameter and 6.4 module. The machine can be configured for dry or wet hobbing.

The company also offers the FFG Werke Modul H200 vertical hobbing machine designed for dry cutting applications for small automotive shoulder milling cutters applications, with the option of using oil or emulsion. According to deep hole drilling inserts the company, chips are cleanly conveyed from the work area by means of a chute, which is designed to prevent any buildup. The hob head is housed within the tool column, which is tightly fastened to the sturdy machine bed. The tailstock is located on the tool column above the hob head, designed to leave the work area free for workpiece loading and unloading operations.

The Cemented Carbide Blog: tungsten insert holder

Star SU offers the Bourn and Koch 400 H seven-axis horizontal hobbing machine featuring a FANUC CNC and point-to-point array hobbing capability. The machine is designed for longer spline shafts as well as spur and helical gears ranging to 400 mm in diameter and 6.4 module. The machine can be configured for dry or wet hobbing.

The company also offers the FFG Werke Modul H200 vertical hobbing machine designed for dry cutting applications for small automotive shoulder milling cutters applications, with the option of using oil or emulsion. According to deep hole drilling inserts the company, chips are cleanly conveyed from the work area by means of a chute, which is designed to prevent any buildup. The hob head is housed within the tool column, which is tightly fastened to the sturdy machine bed. The tailstock is located on the tool column above the hob head, designed to leave the work area free for workpiece loading and unloading operations.

The Cemented Carbide Blog: tungsten insert holder

Turning Center Tackles Heavy Cutting

GWS Tool Group has acquired Monster fast feed milling inserts Tool Company. This is the fourth acquisition in 2021 for GWS Tool Group, and the second West Coast acquisition by the U.S.-based manufacturer.

Monster Tool manufactures and distributes solid round cutting tools for aerospace, automotive, medical, energy, heavy equipment and die-mold. Second-generation and family owned, Monster operates out of an approximately 40,000 square feet facility with additional real estate gun drilling inserts gun drilling inserts secured for future expansion.

“Monster Tool is a best-in-class cutting tool company with a reputation for producing quality performance cutting tools and delivering them to their customers with the utmost speed and ease,” said Rick McIntyre, GWS’ CEO. “Their added logistics and service expertise are additional areas we will look to integrate into the GWS model to further enhance our service and delivery methods to the betterment of all our customers and partners in distribution.”

Josh Lynberg, owner of Monster Tool, says, “From products and services to customer end markets and culture, there are just so many ways in which our companies align and complement each other. This merger will undoubtedly be for the betterment of our company, employees and customers.”

The Cemented Carbide Blog: parting tool Inserts

GWS Tool Group has acquired Monster fast feed milling inserts Tool Company. This is the fourth acquisition in 2021 for GWS Tool Group, and the second West Coast acquisition by the U.S.-based manufacturer.

Monster Tool manufactures and distributes solid round cutting tools for aerospace, automotive, medical, energy, heavy equipment and die-mold. Second-generation and family owned, Monster operates out of an approximately 40,000 square feet facility with additional real estate gun drilling inserts gun drilling inserts secured for future expansion.

“Monster Tool is a best-in-class cutting tool company with a reputation for producing quality performance cutting tools and delivering them to their customers with the utmost speed and ease,” said Rick McIntyre, GWS’ CEO. “Their added logistics and service expertise are additional areas we will look to integrate into the GWS model to further enhance our service and delivery methods to the betterment of all our customers and partners in distribution.”

Josh Lynberg, owner of Monster Tool, says, “From products and services to customer end markets and culture, there are just so many ways in which our companies align and complement each other. This merger will undoubtedly be for the betterment of our company, employees and customers.”

The Cemented Carbide Blog: parting tool Inserts

CNC Grinder Shortens Lead Time for Specialty Tooling

Cutting tool technology is advancing in both subtle and significant ways, and shops’ needs are changing as well. It is worth stepping back to take stock of these two important areas of change for cutting tools — namely, how they are designed and made, and how they are being used.

I recently spoke with John Kollenbroich, head of product management for cutting tool supplier Horn USA, about trends he is seeing. Our conversation was in the “IMTS spark” digital platform. Find the full conversation there. Here is bar peeling inserts an excerpt:

Modern Machine Shop: In grooving, turning and part-off tools, you are seeing more demand for tools providing coolant through the tool. There are a couple factors here we’ll talk about: more recognition of the need for this, plus a technology change in this tooling. First, why is through-tool coolant valuable, and why do you think shops are seeing greater need for it?

John Kollenbroich: Getting coolant to the cutting edge is critical for any manufacturing application. It helps in cooling the cutting zone, provides very needed lubrication, and can assist in breaking a chip. Many times, external lines are used to splash coolant near the work zone. Long Chips can easily interfere with this delivery method, possibly knocking the lines out of the way. Additionally, when tools need to be changed or indexed coolant lines fast feed milling inserts might be moved for better access to the tool. Then when the line is put back it is never the same as it previously was. Often times there is a give-and-take methodology used to cover areas being machined with this coolant, so all tools get some cooling, but none of them get ideal cooling. A coolant-through tool allows pinpoint accuracy with a specific direction of coolant pointed exactly at the cutting zone. This coolant supply is typically not affected by chip production, and occasionally, if high pressure is used, it can aid in breaking the chip. We also have applications where the coolant-through tool has shown marked improvement in tool life.

MMS: Through-tool coolant is available on cutters that couldn't offer it before. What has changed in the technology of tool manufacturing to make this possible?

JK: There’s been a big change is the ability to drill small-diameter holes very deep and do this in a production atmosphere. Part of this comes from the drilling machines being able to reach the necessary speeds and holders that provide superior clamping and runout. The other part comes from tools designed specifically for this drilling application. There are cases in manufacturing our tools where we are working with holes around 1 to 1.5 mm in diameter and 10 to 20 diameters deep. We’ve learned to design to take advantage of this. On a coolant-through tool, material could be added in areas that may need additional strength, allowing for the intersecting coolant ports to be drilled accordingly.

MMS: On machining centers in particular, speed is still increasing. Maybe the top speed available to machining center spindles hasn't changed all that much, but the use of higher-speed spindles continues to become more common. So, if the top speed hasn't gone up, the average speed in shops certainly has. How are cutting tool offerings responding to this? What aspect of tool engineering is responding to greater cutting speed?

JK: Machines and tools seem to have a back-and-forth dance in terms of which is leading. Currently, I believe cutting tools are in the lead, being able to withstand extremely high surface speed. This is mainly due to coatings and coating technology. Coatings continue to evolve, with more layers, and different material being used. This is something all tool manufactures are playing with on some level. The changes in coating technology is somewhat more limited, and not as many are playing in this arena. One process that comes to mind is “HiPIMS,” or high-power impulse magnetron sputtering. This process uses microsecond timing of extreme-power pulses. This allows the metal to ionize to nano size particles to be deposited on the tools. This process allows for greater adhesion and coating hardness, while maintaining great lubricity. Additionally, this process has greatly reduced compressive stresses. This reduction allows for smaller edge preps to be used, thus resulting in sharper tools. Think of compressive stresses as something pulling in all directions at the same time. If these stresses are pulling on a sharp edge it can pop the carbide right off. In order to circumvent this issue, edge preps are put on the tool. Basically, honing the edge, which is dulling the tool slightly. All tooling manufacturers must do this to properly support the coating. With HiPIMS you can have much smaller edge preps, and thus a sharper tool, for more free machining. Having a sharper tool allows for longer tool life. In testing against ourselves we have seen improvements of 50% using the HiPIMS coating technology.

MMS: Here is a topic that does not directly relate to the cutting edge, but still can connect to significant time savings: setup time. You are seeing something related to quick-change tooling and its adoption.

JK: Yes. Improvements in tool life add up. The increase allows for lower cost per part, but most of the time, these saving amount to limited returns. One of the reasons for this limiting factor is tool change time. This is a loss of machining time. Sometimes this loss is small, say 5 minutes to change a tool, other times it can be very large, say 30 minutes or more. If you are able to implement quick-change tooling, and consistently swap out new tooling in 1 to 2 minutes, your savings add up quickly. Swiss-style machines are one area where the saving can be very large. A typical insert change on a Swiss-style machine can be 15 minutes per tool. If you are changing out three tools per shift, that’s 45 minutes of non-production time. Now look at quick-change times of 2 minutes, 3 times a day, and you are at 6 minutes. That almost 40 minutes of production you have gained back. Considering a typical machine rate of $100, you just saved $65 that shift. Do that over a week, two shifts per day, and you have gained back almost 400 minutes, or one free shift of production. This could be the difference between needing to add equipment or better utilizing the machines you have.

MMS: Setup time reduction is a way to increase available machining capacity. Another important way that a growing number of shops is exploring is lights-out machining. The cutting tool plays a role here. What is the way to think about tools in unattended machining?

JK: Lights-out machining is a concept that many companies employ, but not all of them are successful. Sometimes there are only certain jobs that can be run due to issues within the machine. Sometimes shops slow down their tools in an attempt to increase tool life, hopefully reaching a full unattended shift. This is not always the correct approach. Tools are developed to cut within certain parameters, and tool life becomes predictable only within the proper window of operation. Once you have predictable tool life, regardless of time in the machine, you can begin to consider unattended operation. Also, another reason for running tools within the proper parameters is chip control. When a tool is underfed, many things can happen. You could be getting premature wear because of more rubbing than cutting, and you could be creating more of a stringy chip that could block coolant flow or cause issues for other tools.

The Cemented Carbide Blog: http://jasonagnes.mee.nu/

Cutting tool technology is advancing in both subtle and significant ways, and shops’ needs are changing as well. It is worth stepping back to take stock of these two important areas of change for cutting tools — namely, how they are designed and made, and how they are being used.

I recently spoke with John Kollenbroich, head of product management for cutting tool supplier Horn USA, about trends he is seeing. Our conversation was in the “IMTS spark” digital platform. Find the full conversation there. Here is bar peeling inserts an excerpt:

Modern Machine Shop: In grooving, turning and part-off tools, you are seeing more demand for tools providing coolant through the tool. There are a couple factors here we’ll talk about: more recognition of the need for this, plus a technology change in this tooling. First, why is through-tool coolant valuable, and why do you think shops are seeing greater need for it?

John Kollenbroich: Getting coolant to the cutting edge is critical for any manufacturing application. It helps in cooling the cutting zone, provides very needed lubrication, and can assist in breaking a chip. Many times, external lines are used to splash coolant near the work zone. Long Chips can easily interfere with this delivery method, possibly knocking the lines out of the way. Additionally, when tools need to be changed or indexed coolant lines fast feed milling inserts might be moved for better access to the tool. Then when the line is put back it is never the same as it previously was. Often times there is a give-and-take methodology used to cover areas being machined with this coolant, so all tools get some cooling, but none of them get ideal cooling. A coolant-through tool allows pinpoint accuracy with a specific direction of coolant pointed exactly at the cutting zone. This coolant supply is typically not affected by chip production, and occasionally, if high pressure is used, it can aid in breaking the chip. We also have applications where the coolant-through tool has shown marked improvement in tool life.

MMS: Through-tool coolant is available on cutters that couldn't offer it before. What has changed in the technology of tool manufacturing to make this possible?

JK: There’s been a big change is the ability to drill small-diameter holes very deep and do this in a production atmosphere. Part of this comes from the drilling machines being able to reach the necessary speeds and holders that provide superior clamping and runout. The other part comes from tools designed specifically for this drilling application. There are cases in manufacturing our tools where we are working with holes around 1 to 1.5 mm in diameter and 10 to 20 diameters deep. We’ve learned to design to take advantage of this. On a coolant-through tool, material could be added in areas that may need additional strength, allowing for the intersecting coolant ports to be drilled accordingly.

MMS: On machining centers in particular, speed is still increasing. Maybe the top speed available to machining center spindles hasn't changed all that much, but the use of higher-speed spindles continues to become more common. So, if the top speed hasn't gone up, the average speed in shops certainly has. How are cutting tool offerings responding to this? What aspect of tool engineering is responding to greater cutting speed?

JK: Machines and tools seem to have a back-and-forth dance in terms of which is leading. Currently, I believe cutting tools are in the lead, being able to withstand extremely high surface speed. This is mainly due to coatings and coating technology. Coatings continue to evolve, with more layers, and different material being used. This is something all tool manufactures are playing with on some level. The changes in coating technology is somewhat more limited, and not as many are playing in this arena. One process that comes to mind is “HiPIMS,” or high-power impulse magnetron sputtering. This process uses microsecond timing of extreme-power pulses. This allows the metal to ionize to nano size particles to be deposited on the tools. This process allows for greater adhesion and coating hardness, while maintaining great lubricity. Additionally, this process has greatly reduced compressive stresses. This reduction allows for smaller edge preps to be used, thus resulting in sharper tools. Think of compressive stresses as something pulling in all directions at the same time. If these stresses are pulling on a sharp edge it can pop the carbide right off. In order to circumvent this issue, edge preps are put on the tool. Basically, honing the edge, which is dulling the tool slightly. All tooling manufacturers must do this to properly support the coating. With HiPIMS you can have much smaller edge preps, and thus a sharper tool, for more free machining. Having a sharper tool allows for longer tool life. In testing against ourselves we have seen improvements of 50% using the HiPIMS coating technology.

MMS: Here is a topic that does not directly relate to the cutting edge, but still can connect to significant time savings: setup time. You are seeing something related to quick-change tooling and its adoption.

JK: Yes. Improvements in tool life add up. The increase allows for lower cost per part, but most of the time, these saving amount to limited returns. One of the reasons for this limiting factor is tool change time. This is a loss of machining time. Sometimes this loss is small, say 5 minutes to change a tool, other times it can be very large, say 30 minutes or more. If you are able to implement quick-change tooling, and consistently swap out new tooling in 1 to 2 minutes, your savings add up quickly. Swiss-style machines are one area where the saving can be very large. A typical insert change on a Swiss-style machine can be 15 minutes per tool. If you are changing out three tools per shift, that’s 45 minutes of non-production time. Now look at quick-change times of 2 minutes, 3 times a day, and you are at 6 minutes. That almost 40 minutes of production you have gained back. Considering a typical machine rate of $100, you just saved $65 that shift. Do that over a week, two shifts per day, and you have gained back almost 400 minutes, or one free shift of production. This could be the difference between needing to add equipment or better utilizing the machines you have.

MMS: Setup time reduction is a way to increase available machining capacity. Another important way that a growing number of shops is exploring is lights-out machining. The cutting tool plays a role here. What is the way to think about tools in unattended machining?

JK: Lights-out machining is a concept that many companies employ, but not all of them are successful. Sometimes there are only certain jobs that can be run due to issues within the machine. Sometimes shops slow down their tools in an attempt to increase tool life, hopefully reaching a full unattended shift. This is not always the correct approach. Tools are developed to cut within certain parameters, and tool life becomes predictable only within the proper window of operation. Once you have predictable tool life, regardless of time in the machine, you can begin to consider unattended operation. Also, another reason for running tools within the proper parameters is chip control. When a tool is underfed, many things can happen. You could be getting premature wear because of more rubbing than cutting, and you could be creating more of a stringy chip that could block coolant flow or cause issues for other tools.

The Cemented Carbide Blog: http://jasonagnes.mee.nu/